WO2019177681A1 - Handling fracturing materials & fluids - Google Patents

Handling fracturing materials & fluids Download PDF

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Publication number
WO2019177681A1
WO2019177681A1 PCT/US2019/000011 US2019000011W WO2019177681A1 WO 2019177681 A1 WO2019177681 A1 WO 2019177681A1 US 2019000011 W US2019000011 W US 2019000011W WO 2019177681 A1 WO2019177681 A1 WO 2019177681A1
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WO
WIPO (PCT)
Prior art keywords
solids
container
outlet
vessel
fluid
Prior art date
Application number
PCT/US2019/000011
Other languages
French (fr)
Inventor
Norbert Erwin STEIGER
Marvin Brad MARCAK
Original Assignee
Page, Anthony
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Page, Anthony filed Critical Page, Anthony
Publication of WO2019177681A1 publication Critical patent/WO2019177681A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/25Methods for stimulating production
    • E21B43/26Methods for stimulating production by forming crevices or fractures
    • E21B43/2607Surface equipment specially adapted for fracturing operations
    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K8/00Compositions for drilling of boreholes or wells; Compositions for treating boreholes or wells, e.g. for completion or for remedial operations
    • C09K8/60Compositions for stimulating production by acting on the underground formation
    • C09K8/62Compositions for forming crevices or fractures

Definitions

  • INVENTORS ANTHONY PAGE; NORBERT ERWIN STEIGER;
  • the present invention discloses a solids system for handling solids for earth fracturing (e.g. proppants and/or additives) , the system for receiving solids fed to it and for expelling solids from it, the system including a support assembly, a hopper assembly on the support assembly, the hopper assembly having a hopper inlet and a hopper outlet, a storage assembly on the hopper assembly with a storage assembly inlet and a storage assembly outlet, the storage assembly outlet in flow communication with the hopper assembly inlet for the flow of solids from the storage assembly to the hopper assembly, the hopper assembly disposed above the support assembly so that solids flow from the hopper assembly down into a space within or defined by portions of the support assembly.
  • earth fracturing e.g. proppants and/or additives
  • wet proppants are fed to a solids system according to the present invention which have a desired moisture content by weight to facilitate such feeding, e.g., but not limited to, a moisture content of 1% to 12%, of about 5%, of about 9%, of about 10%, or about 12%.
  • Any hopper for solids (container, tank, bin) in any system herein or used in any method or process herein may, according to the present inven . tion, have a system or apparatus within or in communication with the hopper to dry solids therein, e.g. proppant or additives, to cool solids therein, and/or to facilitate the flow of solids.
  • dry solids therein e.g. proppant or additives
  • Such drying and/or solids movement facilitation may be accomplished, in certain aspects, by flowing air and/or by .
  • forced air movement introduced at one location or at multiple locations in a hopper, including, but not limited to, at a feed point for solids in an input feed, at an exit point for solids in an exit feed, at multiple points within the hopper, at a top of a hopper, at a bottom of a hopper, in the middle of a hopper or some combination of any two or three of these.
  • Fan(s), blower (s), and/or air jet(s) may be used at any desired location and/or at any desired plurality of locations.
  • air is applied to the solids.
  • suitable gas, gaseous steam, vapor, vapor stream or some combination of these is used. The air, gas etc.
  • the air, gas, etc. may be at ambient temperature, at an elevated temperature to heat solids, or at a lower temperature to cool solids.
  • the air, gas, etc. may be at any desired humidity or it may be substantially moisture-free.
  • the air, gas, etc. is forced through the solids.
  • the air, gas, etc. flows to a surface on the other side of which are solids and the temperature and/or humidity of the solids, e.g. proppants or additives, is/are changed by non-contact heat exchange between the flow of air, gas, etc. and the solids.
  • Any flowline for solids in any embodiment hereof may have one or some of the solids temperature-changing and/or solids movement enhancement systems mentioned in this paragraph.
  • a container for solids, e.g. proppants, e.g. sand, which includes a plurality of individual bins, each with its own walls and outlet, side-by-side in a structure. Walls of the individual units are within the structure and define each individual component bin. It is within certain aspects of the present invention to provide a structure without a plurality of individual bins for containing solids which has outer walls and a support structure with one or with multiple outlets.
  • Such a structure can, in one aspect, hold as much solids as a structure with a plurality of individual bins; and, in other aspects, such a structure can hold more solids than a comparable structure with a plurality of individual bins of the same exterior dimensions.
  • a structure has internal support members but spaces between at least some such members are not closed off.
  • such a structure may be open at the top or closed off.
  • the present invention provides a liquids system for providing liquids for earth fracturing, e.g. water, the liquids system having multiple modules all in fluid communication with a bottom manifold.
  • a liquids system can have a relatively large capacity in gallons, hundreds of thousands (100, 200, 300, 500 thousand), half a million, a million, 1.5 million, 2 million gallons, or more; said liquid providing pressure for either moving liquid out of the liquids system and/or for providing pressure to facilitate the introduction of liquids into and transfer through a pipe, conduit, a line and/or into a well.
  • the present invention in certain aspects, provides a system for providing frac fluid to at least one well, or to multiple wells in sequence or simultaneously, the system including a solids system, a liquids system adjacent to and in contact with the solids system, directly or indirectly, for heat exchange between the solids system and the liquids system.
  • Such a system, or its components individually, may have one or some, in any possible combination, of the following: wherein the solids system provides proppants for the frac fluid and/or additives for the frac fluid; wherein the liquids system provides water for the frac fluid; wherein the heat exchange is one of the transfer of heat from the solids system to the liquids system and the transfer of heat from the liquids system to the solids system; wherein the solids system is a system for handling solids which receives solids fed to it and expels solids from it, the system including a support assembly, a hopper assembly on the support assembly, the hopper assembly having a hopper inlet and a hopper outlet, a storage assembly on the hopper assembly with a storage assembly inlet and a storage assembly outlet, the storage assembly outlet in flow communication with the hopper assembly inlet for the flow of solids from the storage assembly to the hopper assembly, the hopper assembly disposed above the support assembly so that solids flow from the hopper assembly down into a space within or defined by portions of the
  • the liquids system has walls comprised of wall units each of which is one of: of a desired size, is an ISO container, is the frame of an ISO container, or has a frame with ISO container standard dimensions; and a liner within the walls for holding liquid within the walls; wherein the liquids system holds about half a million gallons of liquid or up to one million gallons of liquid; the liquids system, following the fraccing of a- well using liquids from the liquids system, is reusable as a container for fluids, e.g., but not limited to, water, brine, sea water, crude oil, natural gas liquids, flowback liquids, and liquids pumped into and out of a well; the liquids system further including a plurality of modules one on top of the other, each module containing or able to contain liquid, all modules in fluid communication; a manifold at the bottom of the liquids system for receiving liquid from all modules
  • washing and/or dewatering apparatus producing liquids for feeding to the liquids system to be used with the solids to form frac fluid ; and optionally the washing and/or dewatering apparatus producing liquid for recirculation back for combination with solids prior to washing and/or dewatering and/or liquids for the solids system for hydrating or wetting solids if needed, e.g., but not limited to, providing wet proppants with a desired moisture content, e.g., but not limited to, 1% to 12% moisture by weight in a slurry, and optionally blender apparatus for adding additives to the frac fluid and/or chemical injection apparatus for
  • liquid storage systems of the present invention may be used as drilling mud pits, as storage facilities for flowback liquids and material, or as storage facilities and/or for potable water, e.g. but not limited to, for disaster management; storage facilities for potable water for remote accommodation camps; grey and/or black water at sewerage treatment plants; storage facilities for water of any kind for remote communities; storage facilities for feed water for construction sites and/or feed ⁇ water for concrete production, e.g. but not limited to temporary batch concrete manufacture; storage facilities for feedstock solutions, e.g. but not limited to aqueous solutions for feedstock and/or chemical processes and/or methods; storage facilities for water for arable irrigation and/or livestock water supply.
  • feedstock solutions e.g. but not limited to aqueous solutions for feedstock and/or chemical processes and/or methods
  • storage facilities for water for arable irrigation and/or livestock water supply e.g. but not limited to, for disaster management
  • storage facilities for potable water for remote accommodation camps grey and/or black water at sewerage treatment plants
  • compressed gas e.g. air or nitrogen
  • compressed gas may be used at any point or points in a system according to the present invention to further fluidize a fluid with solids therein and/or to further fluidize a slurry or mixture to facilitate flow and/or to assist in maintaining a slurry or mixture in a fluidized state.
  • Compressed air e.g., may be supplied at container or tank inlets, outlets, and/or along container walls to effect such results.
  • Any suitable compressed gas apparatus or device may be used with suitable and appropriate piping, conduits, valves, and controls.
  • Systems and methods according to the present invention provide the pumping of frac fluids to a site, e.g. one or more wells, at which the fluids will be used; the fluids including a proppant/water mixture for fraccing.
  • Systems according to the present invention provide for the processing and/or drying of proppant and, in certain aspects, the transfer of such proppant to a storage or further processing system according to the present invention, and/or the transfer of such proppant with water to another system according to the present invention.
  • Systertis and methods according to the present invention provide for the separation of proppant from a fluid and/or for the removal of a substantial amount of water from a frac fluid, e.g.
  • Systems and methods according to the present invention provide for the maintenance of a frac fluid (e.g. with proppant and water, e.g. with sand and water) in a fluid state in preparation for use downhole in a fraccing operation.
  • a frac fluid e.g. with proppant and water, e.g. with sand and water
  • Systems and methods according to the present invention provide for the collection of produced materials, e.g. frac fluid, flowback, water, proppant, and/or additives, to a central collection facility (for recycling, reclamation, further processing, disposal, production of potable water, recovery of reusable materials such as but not limited to proppant, recovery of natural gas liquids, recovery of oil e.g. for delivery to a refinery, and/or recovery of flare gas (in one aspect without the need to flare the flare gas) , recovery of flare gas for ethylene production on or off site, and/or for the recovery of materials to produce ethylene for delivery to other facilities, e.g. but not limited to chemical facilities and chemical processing facilities.
  • produced materials e.g. frac fluid, flowback, water, proppant, and/or additives
  • a central collection facility for recycling, reclamation, further processing, disposal, production of potable water, recovery of reusable materials such as but not limited to proppant, recovery of natural gas liquids, recovery of oil e.g. for delivery
  • Such systems may provide for the production of materials at a frac site for transfer to another site or to a carrier (rail or truck/tanker), e.g. materials such as ethylene, natural gas liquids, liquid natural gas and/or CNG (e.g. produced from flare gas on site).
  • a carrier e.g. materials such as ethylene, natural gas liquids, liquid natural gas and/or CNG (e.g. produced from flare gas on site).
  • movement enhancing systems using conveyors, gas and/or liquid to enhance solids movement.
  • the components of a movement enhancing system are added beneath any container of any system according to the present invention and in certain aspects are encompassed within the supporting framework for a container or containers and/or are disposed within solids within a container.
  • Container includes vessel, hopper, trailer, line, pipeline, unit, rail car, barge, ship, module, and storage structure, on shore or offshore; and such movement enhancing systems can be used with any container of any system herein, including, but not limited to, those of Figs. 6A, 8A, 9A, 11A, 12A, 13, 16A, 19A, 21A, 21B, 22, 23A, 24A, 26, 27, 28A, and 29A.
  • a system as disclosed in any of these U.S. Patents, appropriately sized and configured, is used: U.S.
  • Such new, useful unique, efficient, nonobvious apparatuses and systems which are able to provide sufficient frac fluid made up from stored water and proppants (and/or additives) for multiple wells, including wells that are relatively near to each other and wells that are separated by large distances, and optionally, doing this simultaneously for multiple wells; and
  • Such new, useful, unique, efficient, and nonobvious apparatuses and systems which provide a stand-alone system for providing frac fluid to one well or to multiple wells; or a system for use with existing frac fluid systems, e.g, but not limited to, those known systems which rely on transported materials, e.g., transport by truck; and
  • New, useful unique, efficient, nonobvious apparatuses and systems for: storing and handling solids and for storing and handling liquids for an operation; and new, useful unique, efficient, and nonobvious methods of use of such systems; in certain aspects such systems and methods for storing, transmitting, and/or providing frac fluids for fraccing operations .
  • Fig. 1 is a schematic view of a system according to the present invention.
  • Fig. 2A is a schematic view of an apparatus according to the present invention.
  • Fig. 2B is a schematic view of an apparatus according to the present invention.
  • Fig. 2C is a schematic view of an apparatus according to the present invention.
  • Fig. 2D is a schematic view of an apparatus according to the present invention.
  • Fig. 2D is a schematic view of an apparatus according to the present invention.
  • Fig. 2E is a schematic view of an apparatus according to the present invention.
  • Fig. 2F is a schematic view of an apparatus according to the present invention.
  • Fig. 3 is a schematic view of a system according to the present invention.
  • Fig. 4 is a schematic view of a system according to the present invention.
  • Fig. 5 presents various prior art known connectors, clamps, and cones for connecting, stacking, and securing together containers.
  • Fig. 6A is a perspective view of a solids storage system according to the present invention.
  • Fig. 6B is and end view of the system of Fig. 6A.
  • Fig. 6C is side view of the system of Fig. 6A.
  • Fig. 6D is a top view of the system of Fig. 6A.
  • Fig. 7A is a perspective view of a base module according to the present invention of the system of Fig. 6A.
  • Fig. 7B is and end view of a component of the module of
  • Fig. 7C is and end view of two connected components of the module of Fig. 7A.
  • Fig. 7D is an enlargement of part of the components as shown in Fig. 7C.
  • Fig. 7E is a perspective view of a base module according to the present invention of the system of Fig. 6A.
  • Fig. 7F is and end view of a component of the module of
  • Fig. 7G is and end view of two connected components of the module of Fig. 7A.
  • Fig. 8A is a perspective view of a lower hopper module according to the present invention of the system of Fig. 6A.
  • Fig. 8B is a side view of a component of the module of Fig.
  • Fig. 8C is a top view of six connected components of the module of Fig. 8A.
  • Fig. 9A is a perspective view of an upper hopper module according to the present invention of the system of Fig. 6A.
  • Fig. 9B is a side view of a component of the module of Fig. 9A.
  • Fig. 9C is a top view of six connected components of the module of Fig. 9A.
  • Fig. 10A is a perspective view of an intermediate storage module according to the present invention of the system of Fig. 6A.
  • Fig. 10B is a side view of a component of the module of Fig. 10A.
  • Fig. 10C is a top view of six connected components of the module of Fig. 10A.
  • Fig. 11A is a perspective view of a top storage module according to the present invention of the system of Fig. 6A.
  • Fig. 11B is and end view of a component of the module of Fig. 11A.
  • Fig. 11C is a top view of two connected components of the module of Fig. 11A.
  • Fig. 11D is a crosssection view of a shedding plate in a system according to the present invention as in Fig. 11A.
  • Fig. 12A is a perspective view of a liquid storage system according to the present invention with five storage levels .
  • Fig. 12B is a perspective view of the system of Fig. 12A with enclosing sides and top removed to show inner fram structure .
  • Fig. 12C is first end view of the system of Fig. 12B.
  • Fig. 12D is a second end view, of an end opposite to the first end, of the system of Fig. 12B.
  • Fig. 13 is a perspective view of a liquid storage system according to the present invention with three storage levels.
  • Fig. 14A is a perspective view of a base and manifold of a storage system according to the present invention, e.g. as in Figs. 12A or 13.
  • Fig. 14B is a perspective view of the system of a support module of the base of Fig. 14A.
  • Fig. 14C is a perspective view of the manifold shown in Fig. 14A.
  • Fig. 14D is an end view of a manifold for a liquid storage system according to the present invention.
  • Fig. 14E is a perspective view of the manifold end of Fig.
  • Fig. 15A is a side view of a storage module for the storage system of Fig. 12A.
  • Fig. 15B is a partially cutaway view of two vertically adjacent storage modules of the system of Fig. 12A showing one module's bottom opening and one module's top opening, with the openings aligned.
  • Fig. 15C shows in crosssection the sealing of openings of modules such as those of Fig. 15B, with the modules staked one on the other.
  • Fig. 15D is a perspective view of a seal system usable with components of systems according to the present invention.
  • Fig. 16A is a perspective view of a system according to the present invention.
  • Fig. 16B is a perspective view of a system according to the present invention.
  • Fig. 16C is a perspective view of a system according to the present invention.
  • Fig. 17 is a schematic of a method according to the present invention for providing frac fluid to a well.
  • Fig. 18A is a perspective view of a solids system according to the present invention.
  • Fig. 18B is a perspective view of a solids system according to the present invention.
  • Fig. 19A is a perspective view of a system according to the present invention.
  • Fig. 19B is a perspective view of a system according to the present invention.
  • Fig. 19C is a perspective view of a system according to the present invention.
  • Fig. 20 is a perspective view of a system according to the present invention.
  • Fig. 21A is a perspective view of a system according to the present invention.
  • Fig. 21B is a perspective view of a system according to the present invention.
  • Fig. 22 is a perspective view of a system according to the present invention.
  • Fig. 23A is a perspective view of a system according to the present invention.
  • Fig. 23B is a side view of the system of Fig. 23A.
  • Fig. 24A is a perspective view of a system according to the present invention.
  • Fig. 24B is a side view of the system of Fig. 24A.
  • Fig. 25A is a perspective view of a manifold for a system according to the present invention.
  • Fig. 25B is a side view of the manifold of Fig. 25A.
  • Fig. 26 is a schematic view of a system according to the present invention.
  • Fig. 27 is a schematic view of a system according to the present invention.
  • Fig. 28A is a perspective view of a container according to the present invention.
  • Fig. 28B is a side view of the container of Fig. 28A, with some side members removed to reveal interior parts.
  • Fig. 28C is a top view of the container of Fig. 28A.
  • Fig. 29A is a perspective view of a container according to the present invention.
  • Fig. 29B is a tope view of the container of Fig. 28A, with a top removed to reveal interior parts.
  • Fig. 30A is a perspective view of a bucket elevator system according to the present invention.
  • Fig. 30B is a front view of the bucket elevator of Fig.
  • Fig. 30C is a side view of the bucket elevator of Fig. 30A.
  • Fig. 31A is a side schematic view of a system according to the present invention.
  • Fig. 31B is a side schematic view of a system according to the present invention.
  • Fig. 32A is a side perspective view of a system according to the present invention.
  • Fig. 32B is a top perspective view of the system of Fig.
  • Fig. 33 is a side perspective view of a system (shown partially) according to the present invention.
  • Fig. 34 is an end perspective view, partially cutaway, of a system according to the present invention used with a ship.
  • Fig. 35A is a side perspective view of a system according to the present invention used with a rail car.
  • Fig. 35B is a end view of the car of Fig. 35A with the end open.
  • Fig. 36A is a side view, partially in crosssection, of a system according to the present invention.
  • Fig. 36B is a side view of a system according to the present invention.
  • Fig. 37A is a perspective view of a system according to the present invention.
  • Fig. 37B is a side view of the system of Fig. 37A.
  • Fig. 37C is a crossection view along line 37C-37C of Fig. 37B .
  • Fig. 37D is a crossection view along line 37D-37D of
  • Fig. 1 shows a system 12 according to the present invention with a Hub System 10 according to the present invention that provides frac fluids to one well or to a plurality of wells 11 each with a wellhead llh.
  • the Hub System 10 may be any system disclosed herein for providing frac fluid.
  • “Frac fluid” includes: any known fluid (including liquid, gas, and mixtures thereof and fluids with additives and/or proppants) used for fraccing; fluid that is water; fluid that is water with proppants; fluid that is water with additives; and fluid that is water with additives with proppants.
  • Additives include any known additive used in a frac fluid.
  • Proppants include any known material used as a proppant, including, but not limited to, natural materials such as sand and synthetic material such as glass or ceramic beads or spheres.
  • the wells 11 have wellbores 11a, lib and 11c, respectively, that terminate at different depths and fractures can be provided from these wells at any desired depth or location using frac fluids from the Hub System 10.
  • the frac fluids provided by the Hub System 10 can be transmitted by a line which is above ground (see line lid), on the ground (see line lie) or below ground (see line Ilf) .
  • Any desired conduits, pipe or pipeline may be used, including any suitable known conduits, pipe or pipeline used for transmitting oil, gas, or fluid suitable for transmitting frac fluid.
  • the chosen conduits, pipe, or pipeline is made of metal, fiberglass, composite, or other suitable synthetic materials .
  • the Hub System 10 can be sized and configured to support a plurality of spaced-apart wells, e.g. two wells, ten wells, fifty wells, or more. Using suitable conduits, etc. and/or optionally other transport, supported wells can be separated by any suitable distance, e.g. but not limited to separated by fifty meters, one hundred meters, five hundred meters, a thousand meters, two thousand meters, or more. Also such a hub system can use existing conduits, etc. between or near wells.
  • Hub System for this Hub System and for any other system herein, it is to be understood that appropriate conduits, controls, pipes, valves, apparatuses, lines, meters, sensors, and other devices are provided for feeding material into containers and for moving material out of containers; e.g., but not limited to, pumping water into or out of a container, pumping proppants into or out of a container, and pumping frac fluid from a system.
  • the Hub System may also include apparatuses and equipment for accomplishing other functions associated with preparing and injecting a frac fluid into a well; e.g. but not limited to washing apparatus, dewatering apparatus, piping, drying apparatus, blenders and chemical injectors.
  • control system CT control system
  • Fig. 1 also one shown in Figs. 2F, 6A, 12A and
  • control system CT Fig. 1
  • Figs. 2F, 6A, 12A controls all controllable items in the system of Fig. 1 or of any system herein; including, but not limited to, any moving apparatus or equipment, pump, valve, sensor, machine, doof, cover, light, filter, inlet, outlet, engine, ventilator, meter, monitor, or device.
  • Fig. 2A shows schematically a Hub System 20 which has a central container 20b surrounded by a material container 20c.
  • the material contained in the material container 20c is: proppants, proppants and additives, or additives.
  • Heat exchange from one container to the other is possible through the walls of the containers; or, optionally, heat exchange apparatus 20d and/or 20e is used to exchange heat or cold between the contents of one container and the other.
  • Such heat exchange can be used to: cool proppants in the material container using water . in the central container which is at a temperature lower than that of the proppants; heat proppants in the material container using heat from water in the central container; and any desired transfer of heat between components.
  • liquid e.g. water
  • such an amount of liquid can be used as a heat sink for heat needed to be transferred and/or dealt with, e.g., but not limited to for cooling rig equipment and/or apparatuses.
  • stored liquids provide a relatively greater pressure head as compared to certain known storage systems.
  • Some known traditional water storage methods utilize tanks which exist in a single level and all of which rest on the ground. As a result, the hydrostatic pressure at the outlets of such storage tanks is limited to the hydrostatic head of the liquid contained therein.
  • multiple stacked modules or units according to the present invention a contiguous body of water is maintained within the various units or modules at a relatively elevated level. The resultant hydrostatic head is therefore greater, leading to an increased outlet pressure and increased discharge rates in terms of fluid velocity and volume.
  • the central container 20b holds water and the material container 20c holds materials (liquid or solid) such as proppants and/or additives.
  • water in the material container 20c surrounds material in the central container 20b.
  • this may be the case - e.g. liquid in the central container with material in the outer container; or liquid in the outer container with material in the inner container .
  • Fig. 2B shows a system 21 according to the present invention which has a central container 21b within an outer container 21c which includes four similar subcontainers 21d-21g.
  • the central container may hold anything disclosed herein and the subcontainers may hold anything disclosed herein, and the container may be used in any suitable system herein.
  • a system 22 may have an inner container 22b surrounded by an outer container 22c.
  • the outer container 22c is made up of a plurality of subcontainers 22d-22s, some or all of which are intercommunicating with each other and/or feed to a common output point or area.
  • each vertical set of sub containers has a bottom outlet which feeds a common outlet (not shown) or feeds a common manifold (hot shown) .
  • Subcontainers may all be of the same size and dimensions; or, as shown of different size and dimensions.
  • heat exchange is possible between the contents of subcontainers and the content of the central container via container walls; or between material in the subcontainer ( s ) and material in the central container using heat exchange apparatus, e.g. apparatuses 22t and 22v. Any single one sub-container may be employed in or for heat exchange.
  • Fig. 2D shows a hub system 23 according to the present invention which has a central container 23b and an outer container 23c. They may contain material (liquid or solids) as described above for the systems of Figs. 1 - 2C) ; and heat exchange is possible as described for these other systems.
  • the outer container 23c is made up of four subcontainers 23d-23g which encompass the central container 23b. There are some spaces SP between the central container and the subcontainers; and there are areas of contact AC between the subcontainers and the central container. These spaces may be void or they may be filled with any desired material (solid or liquid), e.g. but not limited to heat conductive material or insulation. Walls of any container or subcontainer herein may be made of and/or contain any desired material, e.g., but not limited to, heat conductive material or insulation. Such walls may be integral walls or they may themselves be comprised of subcontainers.
  • Fig. 2E shows a hub system 24 (seen from above) with an outer wall made of three abutting segments 24w, 24x, and 24y which form a container 24b for containing material MT (any material or fluid disclosed herein as being in or used for such a container) , which in one aspect is water.
  • material MT any material or fluid disclosed herein as being in or used for such a container
  • the subcontainers may contain any material disclosed herein for subcontainers; e.g., as shown they contain proppants PP, PT, and PS and additives AT.
  • Fig. 2F shows a system 25 with an outer container 25c within which are disposed two proppant containers 24f and two additive containers 24g. Any heat exchange described for any system herein possible with the system 25 may be effected using the containers and/or heat exchangers (not shown) .
  • containers and subcontainers may be any desired shape and configuration (e.g., but not limited to, the circular, generally cylindrical shapes shown in Figs. 2A-2D, the triangular shapes, as viewed ⁇ from above of Figs. 2E and 2F, the block shapes of the subcontainers as shown e.g. in Fig 2C, and the hexagonal shapes of the containers in Fig. 2F) .
  • a Hub System (or part thereof; e.g., but not limited to, only a proppant storage system or container according to the present invention and/or a water storage system according to the present invention) according to the present invention in combination with a typical known generally-truck-transport-based system.
  • Fig. 3 shows a system 310 according to the present invention which has a hub system 300 (as any disclosed herein including, but not limited to, those shown in Figs. 1-4 and Figs. 16A-16C) which supplies frac fluid to wells 320, directly from the system 300 to each well or via a fracturing manifold 340.
  • the hub system 300 may have its own dedicated pumping system PM which pumps directly to each well 320.
  • the hub system 300 is also connected to and can provide fluid through the fracturing manifold 340 using fracturing pumps 350 which can pump frac fluid from the hub system 300.
  • the system 310 also includes items, truck, apparatuses and equipment associated with a typical system which does not have the benefit of this invention's teachings.
  • the system 310 includes: a typical blender 360 connected to a typical hydration unit 370; a chemical unit 380, solids storage tanks 390, and fluid storage tanks 375.
  • the system includes appropriate ground valves, e.g., ground valves 312 (4 shown in the drawing) also known as fracking relay valves, gate valves, or a flow control valves disposed within the flow lines 330, the valves controlling the flow of frac fluid or "fracturing slurry" during each stage of the fracturing and being operated automatically or operated manually by field personnel.
  • ground valves 312 also known as fracking relay valves, gate valves, or a flow control valves disposed within the flow lines 330, the valves controlling the flow of frac fluid or "fracturing slurry" during each stage of the fracturing and being operated automatically or operated manually by field personnel.
  • the functions accomplished by the items 350-390 can be done by the hub system 300 so that the items 350-390 provide a redundant back-up for the system 300.
  • a system 310 provides new and nonobvious improvements to a system as shown in U.S Application Pub. No 2013/0233560, which is incorporated fully herein for all purposes.
  • the present invention provides systems with two hub systems (any system herein for providing frac fluids to wells) so that each well supplied with frac fluids has a main supplier and a backup supplier.
  • a system 40 according to the present invention has a hub system 41 which is the main supplier for supplying multiple wells through frac manifolds 43a and 43b; and a hub system 42 which is the main supplier for supplying multiple wells through frac manifolds 44a and 44b.
  • the hub system 41 is also in fluid communication with the manifolds 44a, 44b so that it can supply frac fluid as needed to the wells associated with these manifolds; and the hub system 42 is also in fluid communication with the frac manifolds 43a, 43b so that it can supply frac fluid as need to the wells associated with these manifolds.
  • the system 40 includes frac trees 20 in communication with the -associated frac manifold; wells 16, each with a wellhead and a wellbore (not shown) ; and pumps, valves, pipes, connections, etc. (not shown) between system parts.
  • the various parts of the frac trees, wellheads, and manifolds, etc., of the system 40 may be as described in U.S. Patent Publication No. 2013/0175038; and a system 40 provides new and nonobvious improvements to a system as shown in U.S Application Pub. No 2013/0175038, which is incorporated fully herein for all purposes.
  • the two systems 41 and 42 may intercommunicate and provide fluid and/or materials to each other, as needed.
  • Figs. 6A - 6D show a system 60 according to the present invention for receiving, containing, and dispensing solids, e.g. proppants or solid additives for frac fluids.
  • the system is supported by base modules 61 and 62, either of which may be deleted.
  • On the base module 62 is secured a lower hopper module 63.
  • On the lower hopper module is mounted an upper hopper module.
  • the two modules 63 and 64 may be combined into one integral module; or the lower base module 63 may be configured to receive all solids from above and the module 64 may then be deleted.
  • An optional intermediate storage module 65 is on the upper hopper module and a top module 66 is on the intermediate module 65.
  • An opening 61a is defined by side walls of the modules 61 and 62 which is sufficiently large for a container, trailer, rail car, blender container, blender, conveyor system, truck or other structure to be moved into and out of or through from one end to the other of the system 60 after receiving solids from the lower hopper module 63.
  • any desired number of storage modules such as modules 65 and 66, may be used.
  • Known clamps 60a, connectors 60b, and/or stacking cones 60c may be used to interconnect one module's components to those of an adjacent module.
  • components of a particular module are ISO containers or they have the dimensions of ISO containers; and known industry double vertical clamp connectors, industry container corners, industry universal bridge clamps, industry twist locks, industry stacking cones, and industry horizontal clamps are used to connect components.
  • a controller CT controls all controllable items, components, and parts of the system 60.
  • the system 60 has engines, motors, power systems, fans, pumps, ventilators, and any other need power source and/or powered equipment all indicated by the labels PS in Fig. 6B.
  • vent openings or radiators RD are provided for heat exhaust and/or heat dissipation out through an open area of the system as indicated by upward pointing arrows. Open areas of the modules 63, 64 provide light to the opening 61a to assist personnel working in or around the opening.
  • Fig. 7A shows a base module 61 which has twelve interconnected subunits (subunits 61b, 61c, 61d) connected with horizontal clamps 61e and provided with dual stacking cones 61f.
  • Components of the base module 62 may be stacked on the module 61 using the double stacking cones 61f (see Figs. 7C and 7D) ; or the components of the module 61 itself may be stacked on each other, e.g. for transport or storage.
  • Openings between beams or members of the subunits may be left open or, as desired, closed off with panels or plates 61g. Any portion of any part of any system herein may be left open or enclosed with suitable plates or panels, e.g.
  • subunits for flow through ventilation and/or for providing light within a part of the system.
  • Such flow through areas can assist in removing heat form engines, pumps, and ehat producing apparatus within any component for the systems.
  • Any desired number of subunits may be used and the subunits may be of any desired dimensions.
  • the subunits are of ISO standard container dimensions .
  • the module 61 has an access ladder 61h.
  • Fig. 7E shows a base module 62 which has interconnected subunits (subunits 62b, 62c, 62d) connected with horizontal clamps 62e and universal bridge clamps 62f.
  • Components of the base module 62 may be stacked on the module 61 using the double stacking cones 61f (see Figs. 7C and 7D) ; or the components of the module 621 itself may be stacked on each other, e.g. for transport or storage. Openings between beams or members of the subunits may be left open or, as desired, closed off with panels or plates 62 g. Any desired number of subunits may be used and the subunits may be of any desired dimensions. In one particular aspect, as is true for each component of each layer of the system 60, the subunits or components are of ISO standard container dimensions.
  • Figs. 8A - 8C show the lower hopper module 63 with six hopper subunits 63b.
  • An access ladder 63c is provided in one of the subunits.
  • Each hopper subunit includes a support frame 63k which may be any desired size and configuration; and, in one aspect, is a standard ISO container frame.
  • Each subunit 63b has a hopper 63d for receiving and dispensing proppants.
  • the proppants exit the hopper 63d through an orifice 63e.
  • a controller 63f controls the exiting proppant flow. Any suitable gate, valve, iris apparatus, or door may be used as the controller.
  • Each subunit may have an interior ladder 63g and a manway with a removable cover 63h.
  • Figs. 9A - 9C show the upper hopper module 64 with six hopper subunits 64b.
  • An access ladder 64c is provided in one of the subunits.
  • Each hopper subunit includes a support frame 64k which may be any desired size and configuration; and, in one aspect, is a standard ISO container frame.
  • Each subunit 64b has a hopper 64d for receiving and dispensing proppants, the hopper defined by sloping walls 64r and 64s. The proppants exit the hopper 64d through an opening 64e. The tops 64m of the hopers 64d are open for receiving proppants from the modules above the module 64.
  • Each subunit may have a ladder 64g.
  • Each subunit may have a caged ladder 65g.
  • Figs. 10A - 10C show an intermediate storage module 65 of the system 60 which has six subunits 65b each with an open top 65t and an open bottom 65m so that proppants can freely flow into and out from each subunit 65b.
  • Each hopper subunit includes a support frame 65k which may be any desired size and configuration; and, in one aspect, is a standard ISO container frame. Components of subunits are connected together by clamps 65p.
  • Figs. 11A - 11C show an upper storage module 66 of the system 60 which has six subunits 66b each with an open bottom 66m so that proppants can freely flow out from each subunit 66b.
  • Each subunit 66b has a solid top 66t with a movable hatch 66h over an opening 66s through which proppants are fed into the subunits 66b.
  • Each hopper subunit includes a support frame 66k which may be any desired size and configuration; and, in one aspect, is a standard ISO container frame. Components of subunits are connected together by clamps 66p.
  • Each subunit may have level monitor systems 66g, 66v for sensing the level of material in the subunits, providing an indication of the amount of material therein.
  • Each subunit has an opening 66s for personnel access with a corresponding cover 66z.
  • Each subunit has a filtration system 66j for filtering air or other fluid exiting from the subunits.
  • each frame in each module is the size (or half size) of a standard ISO container or is the frame of an ISO container.
  • Each module and/or subunit may have an industry standard access ladder located completely within a frame. These ladders can be aligned in adjacent modules so that personnel can ascend from the lowest module to the top of the system using these ladders.
  • multiple modules may be stacked one on top of the other and connected with standard industry connectors, clamps, corners, and stacking cones for stability in both the vertical and the horizontal planes during storage or transport. Similarly such stability is achieved in the final assembled system.
  • any desired side opening of any subunit or module may be closed off with a removable panel or plate.
  • one particular subunit for the lowest base module 61 is made up of a plurality of standard ISO containers, e.g. such a container with a height of 9 feet, 6 and l/4 th inches, a length of 53 feet, and a width of 8 feet 6 inches (as can be true for any of the subunits of any other layer or assembly or module of any system according to the present invention) .
  • a module can be designed to support a maximum of eight or eight and a half such modules fully loaded with material having a bulk density of about or up to 1.75 gm/cm 3 . In one aspect, nine such modules, when empty, may be stacked on each other.
  • modules are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones.
  • modules are secured in the horizontal plane by means of industry-standard horizontal clamp connectors and/or universal bridge clamps.
  • Such modules may be fully enclosed on all sides with panels or plates except for the uppermost and lowermost planes.
  • the sides of the lowermost plane are enclosed and strengthened by panels or plates, e.g. but not limited to such panels with horizontal corrugations, horizontal when viewed as installed, in order to reduce the substrate point loading of the equipment while on-site and while in-service.
  • any unit, subunit, module or frame herein may be strengthened as desired with added structural members, e.g. beams, struts, crossmembers, etc.
  • a unit or module's lower-most bottom plane is interstitially stiffened utilizing structural steel members of, but not limited to, I-Beam, H-Beam, C-Channel, Rectangular hollow section, Square hollow section, T-Bars, and Flat bars, which can be, optionally, plated over with sheet steel plates of a suitable thickness, e.g., a half inch thick.
  • one particular subunit for the upper base module 62 is made up of a plurality of standard ISO containers.
  • such a subunit is a container with a height of 3'2"feet and a length of 53' or636", resulting in a module 61 feet wide and 3'2"feet high.
  • a module like the module 62 can be designed to support a maximum of seven modules fully loaded with material having a bulk density of about or up to 1.75 gm/cm 3 . In one aspect, nine (or eighteen half-height) such modules, when empty, may be stacked on each other.
  • modules are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones.
  • modules are secured in the horizontal plane by means of industry-standard horizontal clamp connectors and/or universal bridge clamps.
  • the module may be fully enclosed on all sides but not on the uppermost and lowermost horizontal planes.
  • Such a module can attach to the top of a module 61 so that the eight ISO multi-modal container corner castings are aligned and the modules are secured in the vertical plane by means of industry standard double vertical clamp connectors.
  • one particular subunit for the lower hopper module 63 is made up of a plurality of standard ISO containers.
  • such a container has a height of 9' 6 W feet and a length of 53' or 636", resulting in a module 53' feet wide and 9' 6 W feet high.
  • a module like the module 63 made of such subunits, can be designed to support a maxiimim of six full-height modules fully loaded with material having a bulk density of up to 1.75 gm/cm 3 .
  • the module has an inverted frustum-shaped hopper or containment membrane, suitably strengthened and supported by and within a standard ISO multi-modal container frame or frame of such overall dimensions; the uppermost horizontal plane of which is unenclosed, facilitating the free-flow of proppant from the adjacent upper hopper module. Free-flow of proppant from the upper hopper module is facilitated using an orifice at the lowermost point of the module.
  • Such modules can be vertically stacked on top of one another to facilitate multi-modal transportation, handling, storage and delivery to site and during operations for the storage of proppant. While in transit on container liners and during storage as individual units, the module may be stacked empty up to nine full standard ISO units high.
  • modules are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones.
  • modules are secured in the horizontal plane by means of industry-standard horizontal clamp connectors and/or universal bridge clamps.
  • one particular subunit for the intermediate storage module 64 is made up of a plurality of standard ISO containers.
  • a module like the module 63 made of such subunits, can be designed to support a maximum of five full-height modules fully loaded with material having a bulk density of up to 1.75 gm/cm 3 .
  • the module in certain aspects has an inverted frustum-shaped member or containment membrane, suitably strengthened and supported by and within the confines of a standard ISO multi-modal container frame or frame of such overall dimensions; the uppermost horizontal plane and lowermost horizontal plane of which are unenclosed, thus facilitating the free-flow of proppant from the upper storage module into the module 64.
  • the modules are designed to be vertically stacked on top of one another to facilitate multi-modal transportation, handling, storage and delivery to site and during operations for the storage of proppant.
  • one particular subunit for the top storage module 65 is made up of a plurality of standard ISO containers.
  • This module is designed to support, as a total maximum, the sum of four full-height modules fully loaded (where appropriate) with material exhibiting a bulk density of about or up to 1.75 g/cm3. While in transit on container liners and during storage as individual units ⁇ , the modules may be stacked empty up to nine full standard ISO units high.
  • units are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones.
  • modules are secured in the horizontal plane by means of industry-standard horizontal clamp connectors and/or universal bridge clamps.
  • proppant is loaded via penetrations on the tops and/or side faces of module 65. Such proppant loading is achieved using dense or dilute phase transfer.
  • Other configurations are designed to be filled via openings in the upper-most horizontal face of module 63 by gravity.
  • one particular subunit for the top storage module 66 is made up of a plurality of standard ISO containers.
  • the module in certain aspects has a rectangular-shaped member or containment membrane, suitably strengthened and supported by and within the confines of a standard ISO multi-modal container frame or a frame of such overall dimensions, the lowermost horizontal plane of which is unenclosed, thus facilitating the free-flow of proppant into the module 65.
  • This module can provide an uppermost layer of the finally assembled system, afford a weatherproof cover, provide a means by which precipitation is collected and shed from the uppermost surface of the composite system, provide a means by which the composite system is charged with proppant materials and provide a means by which the egress of fugitive silica sand dust effected by the exhaust of air due to pneumatic dilute-phase or pneumatic dense-phase filling of the composite system is mitigated, e.g., using a filter, filter housing and/or associated HEPA filter cartridges.
  • the modules are designed to be vertically stacked on top of one another to facilitate multi modal transportation, handling, storage and delivery to site and during operations for the storage of proppant .
  • modules While in transit on container liners and during storage as individual units, the modules may be stacked empty up to nine full standard ISO units high.
  • units are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones.
  • units are secured in the horizontal plane by means of industry- standard horizontal clamp connectors and/or universal bridge clamps .
  • such a system 60a is a multi-module modular proppant storage system with a composite support structure providing a multi-functional proppant delivery tunnel through the structure, one or multiple proppant storage containers for the storage and discharge of proppants utilized in hydraulic fracturing operations including, but not limited to silica sand, resin-coated silica sand, glass beads, ceramic beads, and sintered ceramic proppant of various grades exhibiting a bulk density of up to 1.75 g/cm 3 .
  • the proppant storage container (s) are stacked vertically upon a composite base at an orientation which is normal to the orientation of the composite base.
  • the lowermost storage container has a bottom hatch affixed to the bottom face of an inverted frustum-shaped container.
  • the bottom hatch is movable between an open position and a closed position.
  • Each of the lowermost material storage containers includes inclined surfaces and extending from the respective longitudinal and transverse vertical planes of the storage container thereof toward the bottom hatch.
  • the lowermost storage container is fully open at its uppermost plane allowing the free-flow of stored proppant from vertically adjacent modules, thus forming a contiguous body of stored material within the structure.
  • a joint (or joints) between vertically adjacent modules is sealed by means of a compression seal between two respective sealing faces.
  • a shedding plate SP see. Fig.
  • successive vertically adjacent material material storage containers each having a compression seal and and associated shedding plate, can be arranged in such a manner as to increase desired storage volume in height rather than in area footprint, increasing overall capacity, e.g. in one aspect up to a maximum of seven modules high.
  • Variable, scalable configurations are therefore able to be assembled in vertical stacks of three, four, five, six and seven or more levels high, all on a suitably sized and configured modular composite base.
  • Fig. 11D shows the shedding plate SP mounted on a member of the module 66 with a bracket BR.
  • An interface between part of the module 66 and part of the module 65 is sealed with a compression seal CN housed within aluminum rails Cl and C2 on an optional aluminum backing plate BL.
  • the shedding plate inhibits solids build up in and around the interface of the two modules and inhibits solids flow in and around the seal CN (optionally the seal CN is omitted) .
  • the shedding plate SP also inhibits the build up of solids in the area of the location of the bracket and the area beneath the bracket.
  • Figs. 12A - 12D show a liquid storage system 120 according to the present invention which has multiple storage modules 122 on a base 126 which are in fluid communication with a manifold 124.
  • Each module 122 has a flow channel 122a through which fluid flows to a lower module or to the manifold 124. Fluid exits the manifold 124 through an exit port 124a.
  • the system 120 rfiay be used for any suitable desired fluid, including, but not limited to, water, brine, calcium chloride solution, chemical mixtures, chemical solutions, non-corrosive oil field chemical solutions and suspensions, and solutions with a specific gravity of up to 1.15 g/cm 3 . Plates or panels 126 enclose sides of the system 120.
  • modules may be made of any suitable material, e.g. but not limited to, metal, plastic, fiberglass, fiber reinforced plastic or fiberglass, or composite material, corrugated or not, with a pattern of holes or perforations or not.
  • Any desired level of modules may be used; e.g. five levels as shown in Fig. 12A or three levels as shown in the system 130, Fig. 13.
  • the pressure of all the fluid in the system is transferred through the mass of water in the system to the bottom of the system.
  • Any such system may include a liner 122v of suitable material lining the entire water storage space (as may be for any system herein) .
  • the modules 122 are the size of the frame of standard ISO container fifty three feet long; and the modules are stacked one on top of the other using standard clamps and cones.
  • the base 126 has a plurality of interconnected modules 126a each of which has a support frame 126b.
  • each module 126a is the frame of an ISO container or be a frame of the same dimensions as an ISO container.
  • the manifold 124 is secured to a module 126a.
  • the manifold 124 has a frame 124c with compartments 124d, some of which have openings 124e which align with a corresponding opening 122a of a storage module above the manifold 124. All of the compartments 124d are intercommunicating and the manifold can receive all the water in all the storage modules above the manifold through the openings 124e.
  • a butterfly valve 124g controls fluid flow from the exit port 124a.
  • the openings 124e and the exit port 124a are circular and are sixteen inches in diameter.
  • a system like that of Fig. 12A may have multiple manifolds, each with an inlet for feeding material into the system and with an outlet for expelling material.
  • Any manifold for any system may be located as shown in Fig. 12A, manifold 124, at an edge of a system or, e.g., as shown with the manifold 124y, at an inner area of the system.
  • Each level of a system may have its own manifold. Using such manifolds side-by- side systems like the system 120 can have their manifolds in fluid communication with each other for any desired flow regime between systems.
  • suitable apparatus PI within the system 120 provides an indication of fluid level and/or of internal hydrostatic pressure and/or of volume of liquid within the system 120
  • Figs. 15A - 15C illustrate a seal structure for sealing the interface between two openings of adjacent modules 122, as shown in Figs. 15B, 15C a top opening 122a of one module and a bottom opening 122m of an adjacent module, but usable for any two adjacent openings of any modules herein.
  • a compression ring 122r is provided between the modules. This ring may be a separate member or, as shown, it may be formed integrally of a plate 122p used to close off a portion of the module.
  • a compression seal ring 122s is disposed within the ring 122r and, as shown in Fig. 15C, sealingly abuts the lower surface of the upper module's plate 122tto seal the area around the opening 122m.
  • Stacking cones 122v are used to stack the top module on the lower module.
  • a manifold 124 is provided through a port 124h which has a removable manway cover 124i over it.
  • a system 124s with appropriate sensor parts within the manifold and/or on the manifold provides an indication of the level of fluid and the pressure of fluid in the system.
  • a level display monitor provides a display of fluid level and, as desired, a display of hydrostatic pressure.
  • Ball valves 124w permit fluid communication to pressure transducers 124t which provide a pressure indication.
  • Fig. 15D illustrates a seal 122p which can be used, suitable shaped and configured, as the seal 122s with corresponding spaced-apart seal rails 122n.
  • Such a seal and rails may also be used with two adjacent parts of two adjacent subunits, units, or modules of any system herein to seal their interface.
  • a system 120a which is one particular embodiment of the system 120, has a storage system support structure of standard ISO multi-modal container longitudinal and transverse dimensions and either standard or non-standard height (e.g. but not limited to half-height or quarter-height ) is ⁇ designed to support, as a total maximum, the sum of six full-height modules fully loaded (where appropriate) with material exhibiting a specific gravity of up to 1.15g/cm 3 .
  • the system is designed to have modules stacked vertically, stacked on top of one another, to facilitate multi-modal transportation, handling, storage and delivery to a site and during operations for the storage and discharge of fresh water, brine, etc.
  • modules While in transit on vehicles or on container ships and during storage as individual units, the modules may be stacked empty up to 27 units high (equivalent to 9 full-height standard ISO units) .
  • modules are secured in the vertical plane by means of industry- standard double vertical clamp connectors, and/or industry- standard twist locks and/or industry-standard container stacking cones.
  • modules are secured in the horizontal plane by means of industry-standard horizontal clamp connectors and/or universal bridge clamps.
  • the module may be fully enclosed on all sides. It is advantageous in certain aspects to enclose the lowermost plane and to suitably strengthen it in order to reduce the substrate point loading of the equipment while on-site and especially while in-service.
  • the base support structure and the manifold are of standard ISO multi-modal container longitudinal and transverse dimensions and non-standard height.
  • the module is designed to support, as a total maximum, the sum of six full-height modules fully loaded (where appropriate) with liquid exhibiting a specific gravity of ' up to 1.15g/cm 3 .
  • Such a module is designed to be vertically stacked on top of one another to facilitate multi-modal transportation, handling, storage and delivery to site and during operations for the storage and discharge of fresh water, brine etc. While in transit, e.g. on vehicles or on container ships and during storage as individual units, the modules may be stacked empty up to 27 units high (equivalent to 9 full-height standard ISO units) .
  • modules are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones.
  • modules are secured in the horizontal plane by means of industry-standard horizontal clamp connectors and/or universal bridge clamps.
  • two flanged openings each of suitable , e.g. 16", diameter, are located within a recessed section of the module in way of the transverse vertical faces of the containment area to facilitate both charge and discharge of fresh water or brine solution; and two flanged openings, each of H" diameter and each coupled with a manually operated, 3 ⁇ 4" ball valve to facilitate the separate attachment of two (2) units of hydrostatic pressure sensors and associated data collection and reporting hardware to facilitate the measurement of the volume of water contained within the fully assembled system.
  • two flanged openings, each of 22' diameter to facilitate man-access into the internal volume of module are located in one of the longitudinal vertical planes. Closure of these openings is achieved via a suitable gasket and blind flange or similar structure.
  • Fluid may be pumped into the system through the exit port 124a of the manifold 124.
  • the manifold facilitates both charge (addition) and discharge of water.
  • an external manifold see e.g. Fig. 3 can be offered as an option.
  • the manifold 124 provides both vertical and horizontal integration of the water storage system, in effect a contiguous body of water to be delivered to the hydraulic fracturing equipment .
  • a rate of supply of fluid achieved a system according to the present invention in excess of 3 times greater than that supplied on site by certain traditional on site water storage systems.
  • a module 122 is designed to support, as a total maximum, the sum of five full-height modules fully loaded (where appropriate) with liquid exhibiting a specific gravity of up to 1.15g/cm 3 .
  • the module is designed to be vertically stacked on top of one another to facilitate multi modal transportation, handling, storage and delivery to site and during operations for the storage and discharge of fresh water and / or brine. While in transit, e.g. on container liners, and during storage as individual units, the module may be stacked empty up to 9 units high.
  • modules are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones.
  • modules are secured in the horizontal plane by means of industry-standard horizontal clamp connectors and/or universal bridge clamps.
  • he compression seals 122s between adjacent modules are made of a solid elastomeric polymer 0- ring restrained in the horizontal plane by one integral double ring or by two spaced-apart metallic, concentric retaining rings of appropriate configuration and dimensions for the chosen seal, e.g. rectangular section, attached to or welded to the horizontal bearing plate surrounding the previously noted aperture (s).
  • the internal free edges of the rectangular section are chamfered by a suitable amount to ensure efficient sealing of the 0-ring with the retaining rings.
  • the cross sectional diameter of the 0- ring, combined with the material of construction thereof is designed to provide a compression of between 25% and 40% in order to provide an effective seal.
  • the offset of the two adjacent seal bearing plates is constant, being described and dependent upon the spacing of the vertically stacked modules, the contact between respective modules being made at the incorporated container corner castings and the associated container stacking cones utilized to provide transverse stability to the assembled modules.
  • a lowermost horizontal plane of a module is inclined at an angle of between +1% and +2.5% from the horizontal to promote and insure drainage of the liquid contents towards the opening between adjacent modules.
  • the uppermost horizontal plane of a module is inclined at an angle of between -1% and -2.5% from the horizontal to ensure effective venting of air from the module towards the opening between adjacent modules during charging of the liquid contents.
  • a ladder of standard industrial design is incorporated into a module (and each module or subunit if desired) to provide access to vertically stacked adjacent modules.
  • the ladder is fully within the confines of the standard ISO container dimension limits, but is located externally to the confines of the water containment area.
  • there is only one subunit or module with a ladder or each subunit and module may have a ladder, either "for interior access or for access to a vertically adjacent module.
  • a topmost module (not shown) of the system 120a may have no top opening. It may have one or more manholes with removable closures for accessing the system interior.
  • Such a module can store liquid of a specific gravity of up to 1.15g/cm 3 as a single module and for transportation and storage purposes may be stacked 9-high while empty.
  • Such a module serves as a feed-water tank for the system 120a and is designed to receive liquid from multiple, e.g. two to seven units of vacuum trailers simultaneously.
  • Such a feed water tank is located as desired; and can be vertically stacked on top of one another to facilitate multi-modal transportation, handling, storage and delivery to a site. While in transit, e.g.
  • such a module is a box-like structure, fully enclosed on each longitudinal and transverse vertical planes and both horizontal planes and is incorporated into an ISO multi-modal container frame of standard dimensions, suitably strengthened or a frame of standard ISO container dimensions.
  • such a module (not shown) has these features:
  • a 3" or 4" fill pipe with threaded termination Along each of the longitudinal vertical planes, there exist three 3" or 4" fill pipes with threaded terminations; one of which is located at the center of the vertical longitudinal plane and the others being located towards the ends of the module at a suitable spacing to allow the placement of three vacuum trucks to facilitate simultaneous filling of other modules.
  • a recess In way of the transverse vertical plane opposite to that in which there exists a fill pipe, is a recess to allow the incorporation of a 16" flanged discharge pipe thro .
  • Three square manhole accesses with covers, positioned one in each location along the intersection of the longitudinal and transverse centerlines, at one end of the longitudinal centerline and diametrically opposite at the end of the longitudinal centerline.
  • Any module or part thereof of any system according to the present invention can have panels or plates that are themselves made of insulating material and/or additional insulation material and/or members may be added; e.g., but not limited to, for use in extremely cold conditions or in extremely hot conditions .
  • the manifold 124 of the system has six openings in the uppermost horizontal face of the containment area which correspond to single openings in each of the lowermost water containment modules.
  • Variable, scalable configurations are able to be assembled in vertical stacks of three, four, five and six or more levels high, excluding the composite base to provide the desired storage capacity of each composite system.
  • the water containment modules are stacked vertically adjacent on the base and orientated normal to the composite base.
  • the openings are fitted with retaining rings and an elastomeric O-ring of solid cross-section and which exhibits a suitable degree of compression, thus facilitating a waterproof seal and preventing leakage of the contained liquid material from within the modules.
  • Storage modules are located vertically adjacent of the base using industry-standard container stacking cones and secured in the horizontal orientation by using industry-standard horizontal clamping bridges. Six sets of vertically orientated stacks are assembled horizontally adjacent to one another. Such an arrangement ensures that all liquid contained in the storage units exists as a contiguous volume, joined via the manifold. Additionally, the manifold module has at each end thereof, one flanged aperture of suitable diameter to ensure free-flow of liquids to be charged and discharged from the assembled storage system into and out of the system. Such openings are designed to be fitted with a closing device, e.g. a valve of suitable design so as to enable an operator or an automatic system to rapidly open and close the valve.
  • a closing device e.g. a valve of suitable design so as to enable an operator or an automatic system to rapidly open and close the valve.
  • manifold module can have two flanged or threaded openings located adjacent to each other, separated by a suitable distance so as to allow the fitting of two units of hydrostatic pressure sensors and associated data processing and reporting equipment. Such equipment can indicate the level of liquid contained within the assembled storage system in real-time.
  • such storage systems have materials contained within ISO standard-sized receptacles which provides: ease of handling using containers/equipment that is/are modular
  • deliveries of materials and equipment may be made at opportune times to ensure that minimal personnel are present on site during equipment handling.
  • Certain systems according to the present invention can provide raw materials and fluids for fracturing, including "zipper" fracturing procedures, currently being employed, and such systems provide scalability for larger installations, including multi-well sites, and for possible future technological advancement, for fracturing multiple wells and for fracturing multiple wells simultaneously in large numbers.
  • Fig. 16A shows a system 160 according to the present invention which has multiple proppant (or solids) storage systems 161 (any such suitable system according to the present invention, including, but not limited to, those of Figs. 2A-11A) and a central fluid system 162 (any such suitable system according to the present invention described herein) .
  • a liner 162a lines the central fluid system 162.
  • Solids (and/or a frac fluid with liquid and solids) from each system 161 are pumped in associated lines 162b from each of the eight systems 161 to wellheads 162c.
  • Solids and/or liquids for recharging the systems 161 are delivered to the systems 161, which may be available on site, e.g. solids and/or liquid separated on site from a slurry or mixture on site; and/or solids and/or liquids provided by items 162d, e.g. vehicles, trains or containers, which can be moved under and/or within the systems 161.
  • the items 162d are blender systems for blending solids and liquids, e.g. water and sand.
  • the system 162 includes structural members 162s (eight shown in Fig.l6A; any suitable desired number of these within the scope of the present invention) which are connected together so that they form a sealed container for containing material, mixtures, slurries, fluid component ( s ) , and/or fluids.
  • each line 162b has a pump for pumping material and/or fluid from the systems 161 to the wellheads 162c (as may any line to any wellhead in any system herein) .
  • the wellheads 162c represent any suitable known wellheads, including but not limited to, standard wellheads, e.g. "Christmas tree" wellheads.
  • the structural members 162s may be solid or hollow, with or without an internal skeletal or supporting structure or support beam(s).
  • Fig. 16B shows a system 163 according to the present invention which has multiple proppant (or solids) storage systems 164, with six pairs of two storage systems side-by-side (any such suitable system according to the present invention, including, but not limited to, those of Figs. 2A-11A) and a central fluid system 165 (any such suitable system according to the present invention described herein).
  • a liner 165s (e.g. like the liner in Fig. 16A) lines the central fluid system 165.
  • Solids and/or liquids and/or fluids from each system 164 are pumped in associated lines 164b (several shown; there are lines to each wellhead or portable lines usable for each wellhead) from each of the systems 164 to wellheads 164c (with a pump for each line or pumps for pumping fluids for all lines, pumps not shown) .
  • Solids and/or liquids and/or fluids for recharging the systems 164 are separated on site from slurries or mixtures provided on site and/or are delivered to the systems 164 by vehicles, trains or containers 164d which can be moved under and/or within the systems 164.
  • Fig. 16C shows a system 166 according to the present invention which has multiple proppant (or solids) storage systems 167, with six trios of three storage systems side-by- side (any such suitable system according to the present invention, including, but not limited to, those of Figs. 2A-11A) and a central fluid system 168 (any such suitable system according to the present invention described herein) .
  • a liner 168s lines the central fluid system 168. Solids and/or liquids and/or fluids from each system 167 are pumped in associated lines 167b from each of the eight systems 167 to wellheads 167c.
  • Solids and/or liquids and/or fluids for recharging the systems 167 are separated from slurries and/or mixtures provided on site, or they are delivered to the systems 167 by vehicles, trains or containers 167d which can be moved under and/or within the systems 167.
  • the vehicles etc. may be loaded with solids from the solids systems and/or liquids may be provided by any system according to the present invention.
  • Fig. 17 presents a schematic of a system 170 for a method for providing frac fluid to a well or multiple wells using a solids system 171 according to the present invention (any suitable solids system disclosed herein) and a liquids system 172 according to the present invention (any suitable liquids system disclosed herein.)
  • a mixture from point 174 e.g. a slurry, of liquid and solids is fed to further processing apparatus FP which may include apparatus for washing, dewatering, and/or grading.
  • the apparatus FP produces dry solids DS, e.g.
  • the apparatus FP produces water that is supplied to a mixture point 175, and/or water that is supplied to the system 171 and/or to a water recirculation pipeline for transmission back to the point 174.
  • the system 171 feed proppant to the mixture point 175 from which a frac fluid with proppants is pumped to a blender and/or chemical injector for selective addition of other additives, if desired, and for blending. Finished frac fluid is then pumped to a well or to multiple wells.
  • the mixture pumped from the point 174 may be a slurry of any desired % constituents; e.g., but not limited to, a slurry of 70% to 80% sand, the balance water; or a slurry of 30% to 38% sand, the balance water - by weight.
  • the pumps PM are positive displacement pumps and the pumps PU are centrifugal pumps.
  • one particular module may have one material and another module may have another material; e.g. a single system can provide sand from one module, ceramic proppants from another module, and solid additives from another module.
  • Fig. 18A shows a solids handling/storage, feed system 180 according to the present invention which has a support 181 which defines two access spaces 182a and 182b above which are positioned multiple controlled solids outlets 183 (there are six outlets 183) of solids containers 184.
  • Each container 184 has sloped walls to facilitate solids movement.
  • the containers 184 are supported by support frames 184f.
  • Fig. 18B shows a solids handling/storage, feed system 185 according to the present invention which has a support 186 above which are positioned multiple controlled solids outlets 188 (there are eight outlets 187) of solids containers 187.
  • Each container 187 has sloped walls sloping to two outlets 188 to facilitate solids movement.
  • the containers 188 are supported by support frames 189.
  • a water storage system according to any embodiment of the present invention which is capapble of holding hundreds of thousands or millions of gallons of water can then be used as part of a seawater desalination plant, as a water storage facility for a park or small town, or as a water storage facility for a crop irrigation irrigation system.
  • a liquid storage system according to the present invention is used as a liquids storage pit or as a mud pit for rig operations.
  • Fig. 19A shows a system 190 according to the present invention which has a solids system 191 according to the present invention (e.g., but not limited to, like the systems 60, 180 or 185) and two fluid storage systems 192
  • the system 190 provides solids (e.g. but not limited to proppants) and fluid (e.g. but not limited to water) to an injection manifold 193 (e.g. a high pressure manifold, sometimes called a "bullet” or a "rocket") from which via lines 194 (lines for each wellhead; or movable lines useful with each wellhead) a fluid (e.g. but not limited to a frac fluid) is transmitted to wellheads 195.
  • Pump systems 196 (eight shown) on vehicles 196a pump the materials from the systems 191 and 192, to the manifold 193, and to the wellheads 195.
  • a truck-mounted blending system TK blends fluid components; e.g. in certain aspects, water from the systems 192 is blended with proppants from the systems 191.
  • Fig. 19B illustrates a system 190a, similar to the system 190 (like numerals indicate like parts), but which has eliminated the pumping systems 196 and the manifold 193 and replaced them with systems 199 according to the present invention which provide for the pumping of material, liquid and/or fluid and include pumping apparatus and, if needed, power apparatus, that accomplishes the functions of the systems 193 and 196.
  • systems 199 which provide for the pumping of material, liquid and/or fluid and include pumping apparatus and, if needed, power apparatus, that accomplishes the functions of the systems 193 and 196.
  • a single wellhead may receive fluids from more than one system 199, in series or in parallel .
  • FIG. 19C illustrates that a system as in Fig. 19A or 19B, or any suitable system herein, can be scaled up as desired to provide any desired level or amount of solids storage and processing and/or any desired amount of fluid storage and processing.
  • a system 190c has a solids system 190d, e.g. but not limited to a system 120, and four systems 192.
  • Fig. 20 shows a system 163 located in a remote area RA ⁇ which is supplied via a pipeline 201 and is accessed via a road 202.
  • the system 163 can supply solids and/or liquid and/or fluid(s) via the pipeline 201 to other sites.
  • Any suitable system herein may be used instead of the system 163.
  • any such system may handle and provide recovered water at the site of the system 163 (in Fig. 20) or at another site. Multiple pipelines and/or multiple roads may also be provided.
  • Fig. 21A illustrates a train 210 with multiple cars 211. Some of the cars (or all) may have stacked ISO containers 212 which are components of systems according to the present invention.
  • These containers 212 may be components of a solids storage system according to the present invention or they may be components of a liquids storage system according to the present invention, or both.
  • the train 210 may be transporting empty or full containers to or from a site of use of the solids and/or liquids, and/or to or form a location of a system according to the present invention. Any suitable desired containers and/or rail cars may be used, including, but not limited to, selected ISO containers of desired size and dimensions.
  • a rail line or a track spur adjacent or passing through a system according to the present invention so that rail cars and/or containers may be accessed for loading or unloading near or within a system according to the present invention.
  • a rail line is located so that a train (entire train or part thereof) may pass through a system according to the present invention.
  • Fig. 21B shows a system 216 according to the present invention for storing and processing solids, e.g. but not limited to a system like the system 120 described above. Rail tracks 217 of a rail line pass through and beneath the system 216 so that a train 218 with cars) 219 can move under and within the system 216 for loading and/or unloading of the cars
  • system 216 includes a pit 216a or tank for receiving material from the rail cars and/or for storage.
  • Fig. 22 illustrates a container ship 220 on whose deck are stacked ISO containers 222 which are components of systems according to the present invention. These containers 222 may be components of a solids storage system according to the present invention or they may be components of a liquids storage system according to the present invention, or both.
  • the ship 220 may be transporting empty or full containers to or from a site of use of the solids and/or liquids.
  • Typical crane apparatus 224 is used to load and unload the containers 222 to and from the ship
  • Figs. 23A and 23B show a system 230 according to the present invention which has a plurality of container modules 232 supported in a structure 234.
  • one such modular container is a standard ISO container or is of the dimensions of a standard ISO container.
  • two, three, four or more of the modular containers are a standard ISO container or are of the dimensions of a standard ISO container.
  • structural members of the ISO containers provide structural members of the system 230.
  • Each container module 232 has a top opening 232a for material loading and a bottom outlet 232b for material exit.
  • Via a manifold 236 all material in all container modules is flowable from the system 230.
  • the manifold 236 may have appropriate valves, seals, sensors, and connections (e.g. but not limited to as any shown or described herein) .
  • the system 230 may be used for the storage and provision of liquids, solids, and/or fluids (fluids including, but not limited to, fluids with solids therein) .
  • the system 230 stores frac fluid with water and proppants (e.g. sand or ceramics).
  • frac fluid in "well-ready" and can be pumped from the system 230 into a well.
  • the additional water is added to the frac fluid and then it is pumped into a well.
  • Any suitable pipeline, pipe or other conduit may be used between the system 230 (of any desired length) between the system 230 and the well.
  • additional additives for facilitating fraccing and/or fluid recovery may be added to the frac fluid.
  • any suitable pump system (s) and apparatuses may be used to pump material from the system 230 to the well.
  • Figs. 24A and 24B show a system 240 according to the present invention which has a plurality of container modules 242 supported in a structure 244.
  • one such modular container is a standard ISO container or is of the dimensions of a standard ISO container.
  • two, three, four or more of the modular containers are a standard ISO container or are of the dimensions of a standard ISO container.
  • structural members of the ISO containers provide structural members of the system 240.
  • Each container module 242 has a top opening : 242a for material loading and a bottom outlet 242b for material exit. Via a manifold 236 (liked that of Fig. 23A) all material in all container modules is flowable from the system 240.
  • the container modules 242 may have inclined walls both at the bottom and at the top, as shown, to facilitate fluid flow.
  • the system 240 stores frac fluid with water and proppants (e.g. sand or ceramics).
  • frac fluid is "well-ready" and can be pumped from the system 240 into a well.
  • the additional water is added to the frac fluid and then it is pumped into a well.
  • Any suitable pipeline, pipe or other conduit may be used between the system 240 (of any desired length) between the system 240 and the well.
  • additional additives for facilitating fraccing and/or fluid recovery may be added to the frac fluid.
  • any suitable pump system (s) and apparatuses may be used to pump material from the system 240 to the well.
  • Figs. 25A and 25B show a manifold 236 which may have any of the valves, parts, connections, sensors, and/or piping of any manifold shown or described herein.
  • the manifold 236 has a plurality of openings 236a, one each corresponding to bottom outlets of containers supported above the manifold for receiving material flowing for the containers.
  • the openings 236a communicate with piping 236b which provides for the flow of the material to an outlet 236c via outlet pipe 236d which is in fluid communication with the piping 236b.
  • Certain typical frac fluid provision systems include silos and containers for holding materials used in fraccing operations and roads to and from them for trucks to bring material to the silos, etc. and to move the materials from the silos, etc. to the sites of wells.
  • these can include one or some of load-out silos, shale play transload silos (long range and short range) , local load out silos, rail load out silos, sand (or resin coating and/or or other solids) storage, and the roadways interconnecting these for truck access.
  • frac fluid (with full moisture content or with partial moisture content) may be provided to any of a number of well sites ("TO WELL SITE") via a pipeline or pipelines 262a - 262i.
  • TO WELL SITE well sites
  • . frac fluid which includes water and sand with a known moisture content, e.g. a moisture content which permits pumping of the fluid, is pumped from a system 264a or 264b to a well site.
  • a known moisture content e.g. a moisture content which permits pumping of the fluid
  • the pipelines in Fig. 26 include suitable and appropriate valves, connections, pumps, piping, sensors, and controls to effect the pumping of fluid to the wellsites, and, optionally, mixing or blending apparatus and/or additive injection or introduction apparatus.
  • the moisture content is such that no additional water is added before pumping into a well; or as shown, additional fluid (e.g.
  • a finalized frac fluid for introduction into a wellbore.
  • varying concentrations of sand suspended in an aqueous medium are achieved by using a "flotation cell" into which compressed air is introduced into a mixture or a slurry at a pre-determined and calibrated rate and volume. By varying the rate of introduction of the compressed air into the system, a desired aqueous medium is achieved.
  • the systems 265 are any suitable known systems herein for the storage of and provision of fluid for fraccing.
  • the system 260 may include one or more blender apparatuses 266 used in conjunction with the material flowing in a pipeline to further blend the material in the pipeline; and/or for such blender apparatuses to add material, proppants and/or additives to the flow in a pipeline, blend the materials, etc. and re-introduce them back into the pipeline .
  • the railcar 269a it is within the scope of the present invention to provide sand from, e.g., a frac sand source such as, but not limited to, a frac sand mine FSM with rail access, directly for a pipeline (e.g. the pipeline 262f) .
  • the rail line and rail cars provide sand (or other proppants or additives) to the system 264a.
  • the system 264a can include one system for providing frac fluid or frac fluid needing additional moisture, or it can includes multiple systems in series or parallel (e.g. as the system 264a as shown with two fluid provision systems x and y) .
  • Rail may also be used to provide sand (or other solids) to any system herein, e.g. as shown by the railcar 269b providing sand from the frac sand mine FSM to the system 264b and/or 264c. Also, sand e.g. from the system 264c may be provided to the system 264b as needed.
  • multiple storage systems can supply a single well .
  • Any pipeline in any system herein may be used to pump recovered water, recovered sand, and/or any flowback fluid from a well back to any of the systems of Fig. 26.
  • Any fluid produced from a well and/or water and/or any hydrocarbons, natural gas liquids ("NGLs"), and/or oil and/or flare gas may be fed to a plant 268 at any desired location through any chosen pipeline for procession and/or further transmission.
  • a separated fluid, etc. can be fed, e.g. via pipeline, to another site and/or to a rail line and to suitable cars on the rail line (e.g. the rail line with the car 269a) .
  • the flare gas is collected (either chemically or physically) and/or processed and/or separated and transferred by rail and/or by pipeline.
  • a system 270, Fig. 27, is like the system 260 (like numerals indicate like parts) and it includes pipeline 262a, system 264a, items 265, 262c,
  • system 270s Via pipelines 270a and 270b, the system 264a can service additional wellheads in systems 270c and 270d (like the system 270s) . It is within the scope of the present invention for a system according to the present invention e.g., but not limited to, as shown in Figs. 26 and 27 to service any desired number of well, with suitable pipelines and/or rail access.
  • materials e.g. solids and/or liquids and/or fluids with solids therein
  • suitable tanks, containers, or silos are transported by truck/trailer/tank and are stored on or off site in suitable tanks, containers, or silos.
  • Fluids herein includes fluids with solids therein.
  • Figs. 28A-28C show a system 280 according to the present invention which includes a solids storage container system 281, e.g. for proppants, e.g. for sand.
  • the interior of the container includes sloping walls 281a, 281b and side walls 281c.
  • the container has ends 280k.
  • Openings 281d allow air flow from beneath the walls 281a, 281b up into the sand within the container. Air at ambient temperature may flow through openings 281e, 281f to the openings 281d.
  • a fan 281g positioned at each opening 281e, 281f pulls air from outside the container 281 into space within the container below the walls 281a, 281b.
  • Optional apparatuses 281h may dehumidify, heat, or cool the air pulled into the container by the fans 281g; and/or supply a gas or vapor, or combination thereof, other than air or in addition to air; and/or they may provide a treatment to proppants including, but but not limited to, any known treatment for any proppant .
  • the openings 281a, 281b are sized, shaped, located and configured so that dams 280j of solids build up over them, which allow air or gas flow.
  • these openings are covered with suitable screen or mesh to facilitate dam formation.
  • a fan or fans 280i are provided for the container to facilitate exhaust of air or gas from within the container. Arrows indicate the path of air flow into and out of the container 281.
  • Figs. 29A and 29B show a container structure 290 which has a beam support network 291 including beam support members 291a - 291d on the structure's exterior and beam support members 291e - 291g interconnected within the structure 290.
  • Exterior walls 292a - 292e define parts of sides of the structure 290 and bottom walls 293a, 293b along with outlet walls 294a, 294b define part of the bottom of the structure.
  • Such a structure may have any desired number of outlets for the exit of solids therefrom.
  • the structure 290 has six outlets 295 (three clearly visible in Fig. 29B) .
  • an . enclosed ladder structure 296 within a corner 297 of the structure 290 provides access to various levels of the structure 290.
  • Such a structure can store, e.g., sand which is all substantially the same; or it can store sands that are different, e.g., in the structure 290 from one to six different grades of sand.
  • the present invention provides a bucket elevator for loading solids into a container and the main parts of the system for receiving, holding, and ejecting the solids into the container are sized and configured so that they fit within a standard ISO container and are then easily transportable to a site for use.
  • Figs. 30A - 30C show a elevator system 300 according to the present invention within a standard ISO container framework FW.
  • a subsystem 301 provides the functions of loading solids into buckets 303 (shown schematically with dotted lines) of a moving subsystem 302 and of powering movement of the subsystem 302. As shown in Figs. 30A - 30B, the subsystem 302 has been raised by the subsystem 301.
  • the framework FW of the ISO container may be used at a site as a support for the bucket elevator system.
  • a stair system 304 (shown in dotted lines in Fig. 30C) is provided for personnel to access the elevator and/or to access different levels of a container which can be loaded using the elevator.
  • Such an elevator system may be positioned within any suitable container according to the present invention; or it may be disposed outside the container, with appropriate connections, opening, conduits, and piping to move solids from the elevator's buckets into the container.
  • Such an elevator system can provide solids into a container at any selected level of multiple levels of the container and/or at multiple levels of solids already within the container.
  • each may have its own dedicated elevator system or one system can be movable to provide solids to each individual container.
  • Fig. 31A shows a system 310 according to the present invention which has a container 312, e.g. but not limited to a hopper for solid proppants, with solids 314 therein.
  • a movement enhancing system 316 is in communication with the container 312 via suitable openings to enhance the flow of solids from the container 312 and/or to enhance the movement of the solids from
  • the container to another structure, e.g., but not limited to, into another container, into a flow line, into a pipeline, into a truck-trailer, or_into a railcar.
  • another structure e.g., but not limited to, into another container, into a flow line, into a pipeline, into a truck-trailer, or_into a railcar.
  • Fig. 31B shows a system 3l ’ l according to the present invention which has containers 313, e.g. but not limited to hoppers for solid proppants, supported by a support structure
  • Each container has solids 315 therein.
  • a movement enhancing system 317 in communication with a corresponding container 311 via suitable openings to enhance the flow of solids from the containers 311 and/or to enhance the movement of the solids from the containers to another structure, e.g., but not limited to, into another container, into a flow line, into a pipeline, into a truck trailer, or into a railcar.
  • the systems 317 are within the containers 311 within the solids 315, as shown by the dotted lines in Fig. 31B.
  • Figs. 32A and 32B shows a system 320 according to the present in invention with a support frame 322 supporting a solids container 324, e.g. but not limited to a ⁇ hoppers for solid proppants, configured for solids exit from the bottom of the container. Solids are introduced into the container via top opening 326 and exit from a bottom opening 327 into a movement enhancing system 328.
  • the container 324 may be a container made to meet ISO requirements, and/or it may be an appropriate ISO shipping container. In one particular aspect, the container 324 is 8 feet long, 7.2 feet wide, and 7.6 feet tall.
  • Fig. 33 shows a system 330 according to the present invention which has multiple containers 334 (not all shown), e.g., but not limited to hoppers for solid proppants, each with a lower solids movement enhancing system 338.
  • a support structure 332 supports the containers 334 and the systems 338.
  • the systems 338 are encompassed completely by the structure 332; but they may have parts that project outside the structure.
  • Fig. 34 shows a container ship SP with multiple containers 344 stacked therein so that upper containers are in communication with lower containers for the flow of solids from the uppermost container down to the lowermost container.
  • Each of the lowermost containers has an associated solids movement enhancing system 348.
  • Fig. 24A, or Fig. 29A with one or with multiple movement enhancing systems, e.g. but not limited to, as shown in Figs. 31B or Fig. 33.
  • Figs. 35A and 35B show a railcar RC with lower solids movement enhancing systems 350 for facilitating the removal of solids from the railcar.
  • damp sand is loaded into a railcar according to the present invention.
  • Such loading of damp sand reduces or eliminates fugitive dust, e.g. but not limited to, fugitive silica dust.
  • Offloading of the sand is facilitated by using one or more movement enhancing systems according to the present invention with no fugitive duct .
  • the solids movement enhancing systems in the systems of Figs. 31A - 35A are a desander- accumulator system such as that disclosed in U.S. Patent 6, 119, 779.
  • such a system includes a fluidizing unit into which liquid (e.g. but not limited to, water) is introduced to mix with material (e.g. but not limited to, sand) being unloaded to form a material/liquid slurry which flows into another container, etc.
  • liquid e.g. but not limited to, water
  • material e.g. but not limited to, sand
  • such systems for facilitating unloading include a container, etc. with an opening or openings through which unloaded material flows down from an upper container, etc. into a lower container, etc.
  • a fluidizing unit or apparatus, or units which receives the material being unloaded (from an upper container, etc.).
  • Liquid, e.g. water, flowing into the fluidizing unit(s) produces a stream flowing down into the container, etc. in the form of material/liquid slurry.
  • the material/liquid slurry from the lower container, etc. is flowed to or is pumped to: another container; a pipeline; a railcar; another vessel; a tank; to other storage or processing equipment; or to any container, etc. disclosed in any embodiment or system herein according to the present invention.
  • the slurry from the lower container is flowed to or pumped to a manifold from which the slurry can be directed as desired to a single line or simultaneously to multiple lines as selected.
  • water is supplied to fluidizing unit(s) and the unit is designed, sized, structured, and configured so that swirling action or a vortex is created within the unit(s) to enhance slurry formation and/or homogeneity.
  • Such motion or action may facilitate flow of material from an upper container to a lower container.
  • the upper container e.g. but not limited to, a railcar containing sand
  • a lower container of a system according to the present invention may have multiple top openings for receiving material from one or all of an upper container's discharge openings; in one aspect, the lower container receives material simultaneously from all of an upper container' s discharge openings .
  • the system for facilitating material unloading can be within a support structure which supports a container, etc. (e.g. a railcar) above the system; e.g.
  • the system for facilitating unloading is below grade (e.g. below the ground level of the level of a rail line) so that the railcar simply has to be brought to stop over the system for unloading.
  • a system SST, or systems, according to the present invention (Fig. 21B) is below grade and has fluidizing unit(s) FDT so that material (e.g. but not limited to, sand) can be unloaded from the cars 219.
  • material e.g. but not limited to, sand
  • Fig. 36A shows a system 360 according to the present invention for facilitating unloading of material ML from a railcar RL.
  • Material flows from the railcar RL (arrow AR) down into and through an opening OP in a container CT of a system SSM according to the present invention.
  • the material ML is initially received by a fluidizing unit FT into which liguid (e.g. but not limited to, water) is pumped (arrow AO) by a pump system PT .
  • the pump system may be located as desired, below grade, above grade, in the container, on the container, in the railcar, or on the railcar.
  • the unit FT produces a slurry with material (arrow AW) .
  • Fig. 36B shows a system 361 including an unloading system and a loaded railcar according to the present invention the system including apparatus and structures for facilitating unloading of material MM from a railcar RR.
  • Material flows from the railcar RR (arrows AA) down into and through reception structures RC, through fluidizing units FZ into a container CN according to the present invention (and which is, e.g., like any container herein, including but not limited to the container CT of Fig. 36A in any of its forms) .
  • Liquid e.g. but not limited to, water
  • a pump system PP is pumped (arrows AS) by a pump system PP.
  • the pump system may be located as desired, below grade, above grade, in the container, on the container, in the railcar, or on the railcar.
  • the unit FT produces a slurry with material (arrows AB) .
  • the railcar RR may be at grade and the container CN below grade; and/or the railcar RR may be on a support above the container CN (with the container at, above, or below grade) .
  • evacuation apparatus ET removes material from the container CT for storage, for further processing, for transfer, for transport, or for transmission (e.g. but not limited to, into a conduit op pipeline) .
  • a container may have multiple bottom openings through which material can be discharged for unloading; for example, the railcar RL may have multiple openings OS, shown in dotted lines in Fig. 36; and/or the container CT can have multiple systems SST, shown in dotted lines in Fig. 36, like the system SSM for receiving discharged material (or the systems SST may be like any systems herein for unloading a railcar) .
  • the container CT may be of any dimensions, e.g. of any diameter or of any height (as shown by the curved line at the bottom of the container in Fig. 36) .
  • Such systems for facilitating material unloading may be used with a single rail line or with multiple adjacent rail lines, or in a rail yard.
  • Figs. 37A - 37D show a system 370 according to the present invention for facilitating unloading of material from a container, e.g., but not limited to, sand from a railcar.
  • the system 370 has a container 372 with receivers 371a in fluid communication with openings 371.
  • a fluidizing unit 373 is disposed in or beneath each opening 371.
  • the units 373 may be wholly or partially within the receivers 371a.
  • the system 370 has interconnected structural and support beams 378a-378e and/or known ISO container corners 378k. Multiple cross beams (not shown) may be used along the length of the container.
  • a system e.g. as shown in Fig. 36 or in Fig. 37A, conforms to selected ISO dimensions and standards.
  • a system is made, designed, configured, sized, and of appropriate materials (e.g., metal, plastics, wood, composites, fiberglass, etc.) to handle and support the material from a fully-loaded railcar, e.g., in one aspect, about 286,000 pounds.
  • Water under pressure is supplied to the units 373 through connections 375 by a system 374, forming a slurry of material and water that flows into the container 372.
  • This slurry is removed from the container 372 through connections 376 by a suitable removal system 377.
  • the slurry is provided to a manifold 378 for further transfer through a single line coming from the manifold or through multiple lines from the manifold, individually, sequentially, or all simultaneously, for further transmission, transfer, or transport (e.g. but not limited to, to a short, medium length, or long pipeline or transmission line) or to any container, pipe, conduit, vessel, tank, or storage structure of any system herein.
  • the fluidising units for use in the systems herein may be those in these U.S. Patents and Applications, all incorporated fully herein for all purposes (with appropriate connections, conduits, controls, materials, flow lines, etc. properly sized): 9,527,013; 8,628,276; 8,371,323; 7,082,955; 7,066,207; 6,749,374; 6,659,118; 5,853,266; 5,195,582; 3,973,802; and U.S. Patent Applications Ser. Nos. 10/525,773 published Nov. 24, 2005 and 11/997,533 published on Sept. 11, 2008.
  • Certain systems of the present invention for unloading material as described above, e.g. Figs. 36A, 36B and 37A: reduce dust generated in material unloading; reduce the need for or eliminate the need for traditional trains or traditional numbers of railcars; reduce the need for or eliminate traditional trans-loading facilities; reduce or eliminate the need for specialized railcars for unloading or specialized equipment; reduce the size of required rail lines or rail yards; can be installed in or associated with rail line sidings; and may be used in dust-sensitive or dust-free environments.

Abstract

Apparatuses and systems for fluid and materials storage, handling, and processing; the fluids and materials useful for earth fracturing; and the systems and methods useful for fracturing a plurality of wells in the earth. This abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to ascertain the subject matter of this disclosure and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims, 37 C.F.R. 1.72(b).

Description

HANDLING FRACTURING MATERIALS & FLUIDS
INVENTORS: ANTHONY PAGE; NORBERT ERWIN STEIGER;
MARVIN BRAD MARCAK
The present invention, in certain aspects, discloses a solids system for handling solids for earth fracturing (e.g. proppants and/or additives) , the system for receiving solids fed to it and for expelling solids from it, the system including a support assembly, a hopper assembly on the support assembly, the hopper assembly having a hopper inlet and a hopper outlet, a storage assembly on the hopper assembly with a storage assembly inlet and a storage assembly outlet, the storage assembly outlet in flow communication with the hopper assembly inlet for the flow of solids from the storage assembly to the hopper assembly, the hopper assembly disposed above the support assembly so that solids flow from the hopper assembly down into a space within or defined by portions of the support assembly. In certain particular aspects, wet proppants are fed to a solids system according to the present invention which have a desired moisture content by weight to facilitate such feeding, e.g., but not limited to, a moisture content of 1% to 12%, of about 5%, of about 9%, of about 10%, or about 12%.
Any hopper for solids (container, tank, bin) in any system herein or used in any method or process herein may, according to the present inven.tion, have a system or apparatus within or in communication with the hopper to dry solids therein, e.g. proppant or additives, to cool solids therein, and/or to facilitate the flow of solids. Such drying and/or solids movement facilitation may be accomplished, in certain aspects, by flowing air and/or by. forced air movement introduced at one location or at multiple locations in a hopper, including, but not limited to, at a feed point for solids in an input feed, at an exit point for solids in an exit feed, at multiple points within the hopper, at a top of a hopper, at a bottom of a hopper, in the middle of a hopper or some combination of any two or three of these. Fan(s), blower (s), and/or air jet(s) may be used at any desired location and/or at any desired plurality of locations. In one embodiment air is applied to the solids. In other embodiments, and suitable gas, gaseous steam, vapor, vapor stream or some combination of these is used. The air, gas etc. may be at ambient temperature, at an elevated temperature to heat solids, or at a lower temperature to cool solids. The air, gas, etc. may be at any desired humidity or it may be substantially moisture-free. In certain aspects, the air, gas, etc. is forced through the solids. In other aspects, the air, gas, etc. flows to a surface on the other side of which are solids and the temperature and/or humidity of the solids, e.g. proppants or additives, is/are changed by non-contact heat exchange between the flow of air, gas, etc. and the solids. Any flowline for solids in any embodiment hereof may have one or some of the solids temperature-changing and/or solids movement enhancement systems mentioned in this paragraph.
It is within the scope of the present invention to provide a container (hopper, bin, tank) for solids, e.g. proppants, e.g. sand, which includes a plurality of individual bins, each with its own walls and outlet, side-by-side in a structure. Walls of the individual units are within the structure and define each individual component bin. It is within certain aspects of the present invention to provide a structure without a plurality of individual bins for containing solids which has outer walls and a support structure with one or with multiple outlets. Such a structure can, in one aspect, hold as much solids as a structure with a plurality of individual bins; and, in other aspects, such a structure can hold more solids than a comparable structure with a plurality of individual bins of the same exterior dimensions. Optionally, such a structure has internal support members but spaces between at least some such members are not closed off. As with any structure according to any system of the present invention, as desired, such a structure may be open at the top or closed off.
The present invention provides a liquids system for providing liquids for earth fracturing, e.g. water, the liquids system having multiple modules all in fluid communication with a bottom manifold. Such a liquids system can have a relatively large capacity in gallons, hundreds of thousands (100, 200, 300, 500 thousand), half a million, a million, 1.5 million, 2 million gallons, or more; said liquid providing pressure for either moving liquid out of the liquids system and/or for providing pressure to facilitate the introduction of liquids into and transfer through a pipe, conduit, a line and/or into a well.
The present invention, in certain aspects, provides a system for providing frac fluid to at least one well, or to multiple wells in sequence or simultaneously, the system including a solids system, a liquids system adjacent to and in contact with the solids system, directly or indirectly, for heat exchange between the solids system and the liquids system. Such a system, or its components individually, may have one or some, in any possible combination, of the following: wherein the solids system provides proppants for the frac fluid and/or additives for the frac fluid; wherein the liquids system provides water for the frac fluid; wherein the heat exchange is one of the transfer of heat from the solids system to the liquids system and the transfer of heat from the liquids system to the solids system; wherein the solids system is a system for handling solids which receives solids fed to it and expels solids from it, the system including a support assembly, a hopper assembly on the support assembly, the hopper assembly having a hopper inlet and a hopper outlet, a storage assembly on the hopper assembly with a storage assembly inlet and a storage assembly outlet, the storage assembly outlet in flow communication with the hopper assembly inlet for the flow of solids from the storage assembly to the hopper assembly, the hopper assembly disposed above the support assembly so that solids flow from the hopper assembly down into a space within or defined by portions of the support assembly; wherein the hopper assembly has two subassemblies, a first hopper sub and a second hopper sub, the first hopper sub above the second hopper sub, the first hopper sub having sloping walls to facilitate the flow of solids from the first hopper sub down to the second hopper sub, the second hopper sub having an outlet and walls sloping down to the outlet for the flow of solids out from the hopper assembly; wherein the first hopper sub includes a plurality of first subunits each of which receives and/or has solids therein, each of which is in flow communication with the second hopper sub, each first subunit in flow communication with the storage assembly for the flow of solids from the storage assembly into the first subunits; wherein the storage assembly has multiple storage subunits each in flow communication with the hopper assembly so that solids may flow from each storage subunit to the hopper assembly; wherein the space of the support assembly is disposed, configured and dimensioned for receiving a container, vehicle, trailer, or tank (collectively "container etc.") totally within or partially within the support assembly to feed solids into the container etc. and the container then removable from the space and/or passable through the support assembly from one side thereon to the other; wherein the liquids system has walls comprised of wall units each of which is one of: of a desired size, is an ISO container, is the frame of an ISO container, or has a frame with ISO container standard dimensions; and a liner within the walls for holding liquid within the walls; wherein the liquids system holds about half a million gallons of liquid or up to one million gallons of liquid; the liquids system, following the fraccing of a- well using liquids from the liquids system, is reusable as a container for fluids, e.g., but not limited to, water, brine, sea water, crude oil, natural gas liquids, flowback liquids, and liquids pumped into and out of a well; the liquids system further including a plurality of modules one on top of the other, each module containing or able to contain liquid, all modules in fluid communication; a manifold at the bottom of the liquids system for receiving liquid from all modules, the manifold having an inlet and an outlet, the inlet for feeding liquid into the modules and the outlet for the flow of liquid out from the liquids system; wherein the manifold is located in a center of the liquids system or at an edge of the liquids system; a base on which liquids module (s) are supported; all or part of the system is enclosed and/or all or part of the system is insulated; in which the system provides frac fluid to multiple wells simultaneously each well provided frac fluid in a line which is one of: above ground, on the ground, or under the ground; in certain aspects, two wells, four wells, ten wells, twenty five wells, or fifty wells, or more; in which either the solids system encompasses the liquids system or the liquids system encompasses the solids system; lines for pumping solids rom a solids source and liquids from a liquids source to the solids system and the liquids system, the solids source being one of a mine, a crushing facility, a milling facility, a product grading facility, and the corresponding line(s) feeding the solids to washing and dewatering apparatus for providing dry graded material, e.g. but not limited to dry graded sand, to the solids system, with suitable pumps used for moving the solids from source to solids system, the liquids source being one of ocean, gulf, river, lake, railcar, creek, truck trailer, and the corresponding line(s) feeding the liquids to apparatus for mixing the liquids with solids prior to the solid entering washing and/or dewatering apparatus, the washing and/or dewatering apparatus producing liquids for feeding to the liquids system to be used with the solids to form frac fluid ; and optionally the washing and/or dewatering apparatus producing liquid for recirculation back for combination with solids prior to washing and/or dewatering and/or liquids for the solids system for hydrating or wetting solids if needed, e.g., but not limited to, providing wet proppants with a desired moisture content, e.g., but not limited to, 1% to 12% moisture by weight in a slurry, and optionally blender apparatus for adding additives to the frac fluid and/or chemical injection apparatus for adding chemicals to the frac fluid; and/or the system for providing frac fluid simultaneously to multiple wells.
In certain embodiments, liquid storage systems of the present invention may be used as drilling mud pits, as storage facilities for flowback liquids and material, or as storage facilities and/or for potable water, e.g. but not limited to, for disaster management; storage facilities for potable water for remote accommodation camps; grey and/or black water at sewerage treatment plants; storage facilities for water of any kind for remote communities; storage facilities for feed water for construction sites and/or feed· water for concrete production, e.g. but not limited to temporary batch concrete manufacture; storage facilities for feedstock solutions, e.g. but not limited to aqueous solutions for feedstock and/or chemical processes and/or methods; storage facilities for water for arable irrigation and/or livestock water supply.
In any system herein, compressed gas (e.g. air or nitrogen) may be used at any point or points in a system according to the present invention to further fluidize a fluid with solids therein and/or to further fluidize a slurry or mixture to facilitate flow and/or to assist in maintaining a slurry or mixture in a fluidized state. Compressed air, e.g., may be supplied at container or tank inlets, outlets, and/or along container walls to effect such results. Any suitable compressed gas apparatus or device may be used with suitable and appropriate piping, conduits, valves, and controls.
Systems and methods according to the present invention provide the pumping of frac fluids to a site, e.g. one or more wells, at which the fluids will be used; the fluids including a proppant/water mixture for fraccing. Systems according to the present invention provide for the processing and/or drying of proppant and, in certain aspects, the transfer of such proppant to a storage or further processing system according to the present invention, and/or the transfer of such proppant with water to another system according to the present invention. Systertis and methods according to the present invention provide for the separation of proppant from a fluid and/or for the removal of a substantial amount of water from a frac fluid, e.g. lowering moisture content to 10-12% and then transferring the resulting proppant/water mixture to a storage or processing system according to the present invention. Systems and methods according to the present invention provide for the maintenance of a frac fluid (e.g. with proppant and water, e.g. with sand and water) in a fluid state in preparation for use downhole in a fraccing operation.
Systems and methods according to the present invention provide for the collection of produced materials, e.g. frac fluid, flowback, water, proppant, and/or additives, to a central collection facility (for recycling, reclamation, further processing, disposal, production of potable water, recovery of reusable materials such as but not limited to proppant, recovery of natural gas liquids, recovery of oil e.g. for delivery to a refinery, and/or recovery of flare gas (in one aspect without the need to flare the flare gas) , recovery of flare gas for ethylene production on or off site, and/or for the recovery of materials to produce ethylene for delivery to other facilities, e.g. but not limited to chemical facilities and chemical processing facilities. Such systems may provide for the production of materials at a frac site for transfer to another site or to a carrier (rail or truck/tanker), e.g. materials such as ethylene, natural gas liquids, liquid natural gas and/or CNG (e.g. produced from flare gas on site).
It is within the scope of the present invention to promote or facilitate the flow of solids from a container used with any system according to the present invention by using any suitable known system for enhancing such movement; including, but not limited to, fluidization systems, jetting systems, desander/accumulator systems, and slurrying systems, all collectively referred to as "movement enhancing systems," using conveyors, gas and/or liquid to enhance solids movement. In certain particular aspects, the components of a movement enhancing system are added beneath any container of any system according to the present invention and in certain aspects are encompassed within the supporting framework for a container or containers and/or are disposed within solids within a container. "Container" includes vessel, hopper, trailer, line, pipeline, unit, rail car, barge, ship, module, and storage structure, on shore or offshore; and such movement enhancing systems can be used with any container of any system herein, including, but not limited to, those of Figs. 6A, 8A, 9A, 11A, 12A, 13, 16A, 19A, 21A, 21B, 22, 23A, 24A, 26, 27, 28A, and 29A. In certain aspects a system as disclosed in any of these U.S. Patents, appropriately sized and configured, is used: U.S. Patents 9,327,214; 6,119,779; 6,821,060; 5,853,266; 7,179,386; 7,997,419; 8,371,323; 8,628,276; 5,772,127; and 5,039,227.
What follows are some of, but not all, the objects of this invention. It is, therefore, an object of at least certain preferred embodiments of the present invention to provide: New, useful unique, efficient, nonobvious apparatuses and systems for: providing frac fluid to a well or to multiple wells; and
New, useful unique, efficient, nonobvious apparatuses and systems for: storing additives and/or proppants for a frac fluid; storing water for a frac fluid; and systems with both such storage capabilities which, in certain aspects, include side-by-side storage for proppants (and/or additives) and for water; and
Such new, useful unique, efficient, nonobvious apparatuses and systems which are able to provide sufficient frac fluid made up from stored water and proppants (and/or additives) for multiple wells, including wells that are relatively near to each other and wells that are separated by large distances, and optionally, doing this simultaneously for multiple wells; and
Such new, useful, unique, efficient, and nonobvious apparatuses and systems in which the system can advantageously employ the pressure, heat or cold of the additives, proppants, and/or water in storage, transferring, pumping, and/or blending of any of the additives, proppants, and/or water; e.g., but not limited to, heat exchange between two components (directly by heat exchange between containers or by using heat exchange apparatus in contact with one or more components) and/or the use of the pressure of a component, e.g. but not limited to, the use of water pressure provided by water in a container or reservoir according to the present invention, to, e.g. move a component within the system and/or to move completed frac fluid;
Such new, useful, unique, efficient, and nonobvious apparatuses and systems which provide a stand-alone system for providing frac fluid to one well or to multiple wells; or a system for use with existing frac fluid systems, e.g, but not limited to, those known systems which rely on transported materials, e.g., transport by truck; and
New, useful unique, efficient, nonobvious apparatuses and systems for: storing and handling solids and for storing and handling liquids for an operation; and new, useful unique, efficient, and nonobvious methods of use of such systems; in certain aspects such systems and methods for storing, transmitting, and/or providing frac fluids for fraccing operations .
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
Fig. 1 is a schematic view of a system according to the present invention.
Fig. 2A is a schematic view of an apparatus according to the present invention.
Fig. 2B is a schematic view of an apparatus according to the present invention.
Fig. 2C is a schematic view of an apparatus according to the present invention.
Fig. 2D is a schematic view of an apparatus according to the present invention.
Fig. 2D is a schematic view of an apparatus according to the present invention.
Fig. 2E is a schematic view of an apparatus according to the present invention.
Fig. 2F is a schematic view of an apparatus according to the present invention.
Fig. 3 is a schematic view of a system according to the present invention.
Fig. 4 is a schematic view of a system according to the present invention.
Fig. 5 presents various prior art known connectors, clamps, and cones for connecting, stacking, and securing together containers.
Fig. 6A is a perspective view of a solids storage system according to the present invention.
Fig. 6B is and end view of the system of Fig. 6A.
Fig. 6C is side view of the system of Fig. 6A.
Fig. 6D is a top view of the system of Fig. 6A. Fig. 7A is a perspective view of a base module according to the present invention of the system of Fig. 6A.
Fig. 7B is and end view of a component of the module of
Fig .7A.
Fig. 7C is and end view of two connected components of the module of Fig. 7A.
Fig. 7D is an enlargement of part of the components as shown in Fig. 7C.
Fig. 7E is a perspective view of a base module according to the present invention of the system of Fig. 6A.
Fig. 7F is and end view of a component of the module of
Fig.7A.
Fig. 7G is and end view of two connected components of the module of Fig. 7A.
Fig. 8A is a perspective view of a lower hopper module according to the present invention of the system of Fig. 6A.
Fig. 8B is a side view of a component of the module of Fig.
8A .
Fig. 8C is a top view of six connected components of the module of Fig. 8A.
Fig. 9A is a perspective view of an upper hopper module according to the present invention of the system of Fig. 6A.
Fig. 9B is a side view of a component of the module of Fig. 9A.
Fig. 9C is a top view of six connected components of the module of Fig. 9A.
Fig. 10A is a perspective view of an intermediate storage module according to the present invention of the system of Fig. 6A.. Fig. 10B is a side view of a component of the module of Fig. 10A.
Fig. 10C is a top view of six connected components of the module of Fig. 10A.
Fig. 11A is a perspective view of a top storage module according to the present invention of the system of Fig. 6A.
Fig. 11B is and end view of a component of the module of Fig. 11A.
Fig. 11C is a top view of two connected components of the module of Fig. 11A.
Fig. 11D is a crosssection view of a shedding plate in a system according to the present invention as in Fig. 11A.
Fig. 12A is a perspective view of a liquid storage system according to the present invention with five storage levels .
Fig. 12B is a perspective view of the system of Fig. 12A with enclosing sides and top removed to show inner fram structure .
Fig. 12C is first end view of the system of Fig. 12B.
Fig. 12D is a second end view, of an end opposite to the first end, of the system of Fig. 12B.
Fig. 13 is a perspective view of a liquid storage system according to the present invention with three storage levels.
Fig. 14A is a perspective view of a base and manifold of a storage system according to the present invention, e.g. as in Figs. 12A or 13.
Fig. 14B is a perspective view of the system of a support module of the base of Fig. 14A.
Fig. 14C is a perspective view of the manifold shown in Fig. 14A.
Fig. 14D is an end view of a manifold for a liquid storage system according to the present invention.
Fig. 14E is a perspective view of the manifold end of Fig.
14D.
Fig. 15A is a side view of a storage module for the storage system of Fig. 12A.
Fig. 15B is a partially cutaway view of two vertically adjacent storage modules of the system of Fig. 12A showing one module's bottom opening and one module's top opening, with the openings aligned.
Fig. 15C shows in crosssection the sealing of openings of modules such as those of Fig. 15B, with the modules staked one on the other.
Fig. 15D is a perspective view of a seal system usable with components of systems according to the present invention.
Fig. 16A is a perspective view of a system according to the present invention.
Fig. 16B is a perspective view of a system according to the present invention.
Fig. 16C is a perspective view of a system according to the present invention.
Fig. 17 is a schematic of a method according to the present invention for providing frac fluid to a well.
Fig. 18A is a perspective view of a solids system according to the present invention.
Fig. 18B is a perspective view of a solids system according to the present invention.
Fig. 19A is a perspective view of a system according to the present invention.
Fig. 19B is a perspective view of a system according to the present invention.
Fig. 19C is a perspective view of a system according to the present invention.
Fig. 20 is a perspective view of a system according to the present invention.
Fig. 21A is a perspective view of a system according to the present invention.
Fig. 21B is a perspective view of a system according to the present invention.
Fig. 22 is a perspective view of a system according to the present invention.
Fig. 23A is a perspective view of a system according to the present invention.
Fig. 23B is a side view of the system of Fig. 23A.
Fig. 24A is a perspective view of a system according to the present invention.
Fig. 24B is a side view of the system of Fig. 24A.
Fig. 25A is a perspective view of a manifold for a system according to the present invention.
Fig. 25B is a side view of the manifold of Fig. 25A.
Fig. 26 is a schematic view of a system according to the present invention.
Fig. 27 is a schematic view of a system according to the present invention. Fig. 28A is a perspective view of a container according to the present invention.
Fig. 28B is a side view of the container of Fig. 28A, with some side members removed to reveal interior parts.
Fig. 28C is a top view of the container of Fig. 28A.
Fig. 29A is a perspective view of a container according to the present invention.
Fig. 29B is a tope view of the container of Fig. 28A, with a top removed to reveal interior parts.
Fig. 30A is a perspective view of a bucket elevator system according to the present invention.
Fig. 30B is a front view of the bucket elevator of Fig.
30A.
Fig. 30C is a side view of the bucket elevator of Fig. 30A.
Fig. 31A is a side schematic view of a system according to the present invention.
Fig. 31B is a side schematic view of a system according to the present invention.
Fig. 32A is a side perspective view of a system according to the present invention.
Fig. 32B is a top perspective view of the system of Fig.
32A.
Fig. 33 is a side perspective view of a system (shown partially) according to the present invention.
Fig. 34 is an end perspective view, partially cutaway, of a system according to the present invention used with a ship.
Fig. 35A is a side perspective view of a system according to the present invention used with a rail car. Fig. 35B is a end view of the car of Fig. 35A with the end open.
Fig. 36A is a side view, partially in crosssection, of a system according to the present invention.
Fig. 36B is a side view of a system according to the present invention.
Fig. 37A is a perspective view of a system according to the present invention.
Fig. 37B is a side view of the system of Fig. 37A.
Fig. 37C is a crossection view along line 37C-37C of Fig. 37B .
Fig. 37D is a crossection view along line 37D-37D of
Fig . 37B.
DETAILED DESCRIPTION OF SOME EMBODIMENTS OF THE INVENTION
Fig. 1 shows a system 12 according to the present invention with a Hub System 10 according to the present invention that provides frac fluids to one well or to a plurality of wells 11 each with a wellhead llh. The Hub System 10 may be any system disclosed herein for providing frac fluid. "Frac fluid" includes: any known fluid (including liquid, gas, and mixtures thereof and fluids with additives and/or proppants) used for fraccing; fluid that is water; fluid that is water with proppants; fluid that is water with additives; and fluid that is water with additives with proppants. "Additives" include any known additive used in a frac fluid. "Proppants" include any known material used as a proppant, including, but not limited to, natural materials such as sand and synthetic material such as glass or ceramic beads or spheres. The wells 11 have wellbores 11a, lib and 11c, respectively, that terminate at different depths and fractures can be provided from these wells at any desired depth or location using frac fluids from the Hub System 10.
The frac fluids provided by the Hub System 10 can be transmitted by a line which is above ground (see line lid), on the ground (see line lie) or below ground (see line Ilf) . Any desired conduits, pipe or pipeline may be used, including any suitable known conduits, pipe or pipeline used for transmitting oil, gas, or fluid suitable for transmitting frac fluid. Optionally, the chosen conduits, pipe, or pipeline is made of metal, fiberglass, composite, or other suitable synthetic materials .
It is within the scope of the present invention to pump frac fluid from the Hub System 10 into a wellhead (see line lid) below a wellhead (see line lie) or into a wellbore (see line Ilf).
The Hub System 10 can be sized and configured to support a plurality of spaced-apart wells, e.g. two wells, ten wells, fifty wells, or more. Using suitable conduits, etc. and/or optionally other transport, supported wells can be separated by any suitable distance, e.g. but not limited to separated by fifty meters, one hundred meters, five hundred meters, a thousand meters, two thousand meters, or more. Also such a hub system can use existing conduits, etc. between or near wells.
For this Hub System and for any other system herein, it is to be understood that appropriate conduits, controls, pipes, valves, apparatuses, lines, meters, sensors, and other devices are provided for feeding material into containers and for moving material out of containers; e.g., but not limited to, pumping water into or out of a container, pumping proppants into or out of a container, and pumping frac fluid from a system. The Hub System may also include apparatuses and equipment for accomplishing other functions associated with preparing and injecting a frac fluid into a well; e.g. but not limited to washing apparatus, dewatering apparatus, piping, drying apparatus, blenders and chemical injectors.
It is within the scope of the present invention to provide a control system or multiple controls, all indicated by the control system CT, Fig. 1 (also one shown in Figs. 2F, 6A, 12A and) which controls all controllable items in the system of Fig. 1 or of any system herein; including, but not limited to, any moving apparatus or equipment, pump, valve, sensor, machine, doof, cover, light, filter, inlet, outlet, engine, ventilator, meter, monitor, or device.
Fig. 2A shows schematically a Hub System 20 which has a central container 20b surrounded by a material container 20c. In certain aspects, the material contained in the material container 20c is: proppants, proppants and additives, or additives. Heat exchange from one container to the other is possible through the walls of the containers; or, optionally, heat exchange apparatus 20d and/or 20e is used to exchange heat or cold between the contents of one container and the other.
Such heat exchange (and this is true for any heat exchange for any system herein) can be used to: cool proppants in the material container using water . in the central container which is at a temperature lower than that of the proppants; heat proppants in the material container using heat from water in the central container; and any desired transfer of heat between components. With liquid, e.g. water, being periodically or constantly fed to and/or replenished in a central container or liquids storage system or assembly according to the present invention, such an amount of liquid can be used as a heat sink for heat needed to be transferred and/or dealt with, e.g., but not limited to for cooling rig equipment and/or apparatuses.
With certain embodiments of the present invention, stored liquids provide a relatively greater pressure head as compared to certain known storage systems. Some known traditional water storage methods utilize tanks which exist in a single level and all of which rest on the ground. As a result, the hydrostatic pressure at the outlets of such storage tanks is limited to the hydrostatic head of the liquid contained therein. With multiple stacked modules or units according to the present invention, a contiguous body of water is maintained within the various units or modules at a relatively elevated level. The resultant hydrostatic head is therefore greater, leading to an increased outlet pressure and increased discharge rates in terms of fluid velocity and volume.
In one aspect, the central container 20b holds water and the material container 20c holds materials (liquid or solid) such as proppants and/or additives. In another aspect, water in the material container 20c surrounds material in the central container 20b. For any system herein, this may be the case - e.g. liquid in the central container with material in the outer container; or liquid in the outer container with material in the inner container .
Fig. 2B shows a system 21 according to the present invention which has a central container 21b within an outer container 21c which includes four similar subcontainers 21d-21g. The central container may hold anything disclosed herein and the subcontainers may hold anything disclosed herein, and the container may be used in any suitable system herein.
As shown in Fig. 2C a system 22 according to the present invention may have an inner container 22b surrounded by an outer container 22c. The outer container 22c is made up of a plurality of subcontainers 22d-22s, some or all of which are intercommunicating with each other and/or feed to a common output point or area. Optionally, each vertical set of sub containers has a bottom outlet which feeds a common outlet (not shown) or feeds a common manifold (hot shown) . Subcontainers may all be of the same size and dimensions; or, as shown of different size and dimensions.
Optionally, heat exchange is possible between the contents of subcontainers and the content of the central container via container walls; or between material in the subcontainer ( s ) and material in the central container using heat exchange apparatus, e.g. apparatuses 22t and 22v. Any single one sub-container may be employed in or for heat exchange.
Fig. 2D shows a hub system 23 according to the present invention which has a central container 23b and an outer container 23c. They may contain material (liquid or solids) as described above for the systems of Figs. 1 - 2C) ; and heat exchange is possible as described for these other systems.
The outer container 23c is made up of four subcontainers 23d-23g which encompass the central container 23b. There are some spaces SP between the central container and the subcontainers; and there are areas of contact AC between the subcontainers and the central container. These spaces may be void or they may be filled with any desired material (solid or liquid), e.g. but not limited to heat conductive material or insulation. Walls of any container or subcontainer herein may be made of and/or contain any desired material, e.g., but not limited to, heat conductive material or insulation. Such walls may be integral walls or they may themselves be comprised of subcontainers.
It is within the scope of the present invention to provide more than one container within a larger container - e.g. smaller containers for water etc. within a larger container or a number of smaller containers for additives and/or proppants within a larger container of water. Any heat exchange apparatus or method as described herein may be used for the larger container and the smaller containers. Fig. 2E shows a hub system 24 (seen from above) with an outer wall made of three abutting segments 24w, 24x, and 24y which form a container 24b for containing material MT (any material or fluid disclosed herein as being in or used for such a container) , which in one aspect is water. Four subcontainers 24d-24g are spaced apart within the container 24b. The subcontainers may contain any material disclosed herein for subcontainers; e.g., as shown they contain proppants PP, PT, and PS and additives AT.
It is within the scope of the present invention to have a larger container for materials such as proppants and/or additives within which is one or a plurality of container (s) for material such as frac fluid or water. Fig. 2F shows a system 25 with an outer container 25c within which are disposed two proppant containers 24f and two additive containers 24g. Any heat exchange described for any system herein possible with the system 25 may be effected using the containers and/or heat exchangers (not shown) . As shown in various drawings herein, containers and subcontainers may be any desired shape and configuration (e.g., but not limited to, the circular, generally cylindrical shapes shown in Figs. 2A-2D, the triangular shapes, as viewed· from above of Figs. 2E and 2F, the block shapes of the subcontainers as shown e.g. in Fig 2C, and the hexagonal shapes of the containers in Fig. 2F) .
It is within the scope of the present invention to use a Hub System (or part thereof; e.g., but not limited to, only a proppant storage system or container according to the present invention and/or a water storage system according to the present invention) according to the present invention in combination with a typical known generally-truck-transport-based system. Fig. 3 shows a system 310 according to the present invention which has a hub system 300 (as any disclosed herein including, but not limited to, those shown in Figs. 1-4 and Figs. 16A-16C) which supplies frac fluid to wells 320, directly from the system 300 to each well or via a fracturing manifold 340. The hub system 300 may have its own dedicated pumping system PM which pumps directly to each well 320.
The hub system 300 is also connected to and can provide fluid through the fracturing manifold 340 using fracturing pumps 350 which can pump frac fluid from the hub system 300. The system 310 also includes items, truck, apparatuses and equipment associated with a typical system which does not have the benefit of this invention's teachings. For example, the system 310 includes: a typical blender 360 connected to a typical hydration unit 370; a chemical unit 380, solids storage tanks 390, and fluid storage tanks 375. The system includes appropriate ground valves, e.g., ground valves 312 (4 shown in the drawing) also known as fracking relay valves, gate valves, or a flow control valves disposed within the flow lines 330, the valves controlling the flow of frac fluid or "fracturing slurry" during each stage of the fracturing and being operated automatically or operated manually by field personnel. The functions accomplished by the items 350-390 can be done by the hub system 300 so that the items 350-390 provide a redundant back-up for the system 300.
In certain aspects a system 310 provides new and nonobvious improvements to a system as shown in U.S Application Pub. No 2013/0233560, which is incorporated fully herein for all purposes.
The present invention provides systems with two hub systems (any system herein for providing frac fluids to wells) so that each well supplied with frac fluids has a main supplier and a backup supplier. As shown for example in Fig. 4, a system 40 according to the present invention has a hub system 41 which is the main supplier for supplying multiple wells through frac manifolds 43a and 43b; and a hub system 42 which is the main supplier for supplying multiple wells through frac manifolds 44a and 44b.
The hub system 41 is also in fluid communication with the manifolds 44a, 44b so that it can supply frac fluid as needed to the wells associated with these manifolds; and the hub system 42 is also in fluid communication with the frac manifolds 43a, 43b so that it can supply frac fluid as need to the wells associated with these manifolds. The system 40 includes frac trees 20 in communication with the -associated frac manifold; wells 16, each with a wellhead and a wellbore (not shown) ; and pumps, valves, pipes, connections, etc. (not shown) between system parts. For example, and not by way of limitation, the various parts of the frac trees, wellheads, and manifolds, etc., of the system 40 may be as described in U.S. Patent Publication No. 2013/0175038; and a system 40 provides new and nonobvious improvements to a system as shown in U.S Application Pub. No 2013/0175038, which is incorporated fully herein for all purposes.
Optionally, as indicated by the arrow AW, the two systems 41 and 42 may intercommunicate and provide fluid and/or materials to each other, as needed.
Figs. 6A - 6D show a system 60 according to the present invention for receiving, containing, and dispensing solids, e.g. proppants or solid additives for frac fluids. The system is supported by base modules 61 and 62, either of which may be deleted. On the base module 62 is secured a lower hopper module 63. On the lower hopper module is mounted an upper hopper module. The two modules 63 and 64 may be combined into one integral module; or the lower base module 63 may be configured to receive all solids from above and the module 64 may then be deleted. An optional intermediate storage module 65 is on the upper hopper module and a top module 66 is on the intermediate module 65.
An opening 61a is defined by side walls of the modules 61 and 62 which is sufficiently large for a container, trailer, rail car, blender container, blender, conveyor system, truck or other structure to be moved into and out of or through from one end to the other of the system 60 after receiving solids from the lower hopper module 63.
Any desired number of storage modules, such as modules 65 and 66, may be used. Known clamps 60a, connectors 60b, and/or stacking cones 60c may be used to interconnect one module's components to those of an adjacent module. In certain aspects, components of a particular module are ISO containers or they have the dimensions of ISO containers; and known industry double vertical clamp connectors, industry container corners, industry universal bridge clamps, industry twist locks, industry stacking cones, and industry horizontal clamps are used to connect components.
A shown in Fig. 6B a controller CT controls all controllable items, components, and parts of the system 60. Optionally, the system 60 has engines, motors, power systems, fans, pumps, ventilators, and any other need power source and/or powered equipment all indicated by the labels PS in Fig. 6B. Optionally vent openings or radiators RD are provided for heat exhaust and/or heat dissipation out through an open area of the system as indicated by upward pointing arrows. Open areas of the modules 63, 64 provide light to the opening 61a to assist personnel working in or around the opening.
Fig. 7A shows a base module 61 which has twelve interconnected subunits (subunits 61b, 61c, 61d) connected with horizontal clamps 61e and provided with dual stacking cones 61f. Components of the base module 62 may be stacked on the module 61 using the double stacking cones 61f (see Figs. 7C and 7D) ; or the components of the module 61 itself may be stacked on each other, e.g. for transport or storage. Openings between beams or members of the subunits may be left open or, as desired, closed off with panels or plates 61g. Any portion of any part of any system herein may be left open or enclosed with suitable plates or panels, e.g. for flow through ventilation and/or for providing light within a part of the system. Such flow through areas can assist in removing heat form engines, pumps, and ehat producing apparatus within any component for the systems. Any desired number of subunits may be used and the subunits may be of any desired dimensions. In one particular aspect, the subunits are of ISO standard container dimensions .
Optionally, the module 61 has an access ladder 61h.
Fig. 7E shows a base module 62 which has interconnected subunits (subunits 62b, 62c, 62d) connected with horizontal clamps 62e and universal bridge clamps 62f. Components of the base module 62 may be stacked on the module 61 using the double stacking cones 61f (see Figs. 7C and 7D) ; or the components of the module 621 itself may be stacked on each other, e.g. for transport or storage. Openings between beams or members of the subunits may be left open or, as desired, closed off with panels or plates 62 g. Any desired number of subunits may be used and the subunits may be of any desired dimensions. In one particular aspect, as is true for each component of each layer of the system 60, the subunits or components are of ISO standard container dimensions.
Figs. 8A - 8C show the lower hopper module 63 with six hopper subunits 63b. An access ladder 63c is provided in one of the subunits. Each hopper subunit includes a support frame 63k which may be any desired size and configuration; and, in one aspect, is a standard ISO container frame.
Each subunit 63b has a hopper 63d for receiving and dispensing proppants. The proppants exit the hopper 63d through an orifice 63e. A controller 63f controls the exiting proppant flow. Any suitable gate, valve, iris apparatus, or door may be used as the controller. Each subunit may have an interior ladder 63g and a manway with a removable cover 63h.
Figs. 9A - 9C show the upper hopper module 64 with six hopper subunits 64b. An access ladder 64c is provided in one of the subunits. Each hopper subunit includes a support frame 64k which may be any desired size and configuration; and, in one aspect, is a standard ISO container frame.
Each subunit 64b has a hopper 64d for receiving and dispensing proppants, the hopper defined by sloping walls 64r and 64s. The proppants exit the hopper 64d through an opening 64e. The tops 64m of the hopers 64d are open for receiving proppants from the modules above the module 64. Each subunit may have a ladder 64g. Each subunit may have a caged ladder 65g.
Figs. 10A - 10C show an intermediate storage module 65 of the system 60 which has six subunits 65b each with an open top 65t and an open bottom 65m so that proppants can freely flow into and out from each subunit 65b. Each hopper subunit includes a support frame 65k which may be any desired size and configuration; and, in one aspect, is a standard ISO container frame. Components of subunits are connected together by clamps 65p. Figs. 11A - 11C show an upper storage module 66 of the system 60 which has six subunits 66b each with an open bottom 66m so that proppants can freely flow out from each subunit 66b. Each subunit 66b has a solid top 66t with a movable hatch 66h over an opening 66s through which proppants are fed into the subunits 66b. Each hopper subunit includes a support frame 66k which may be any desired size and configuration; and, in one aspect, is a standard ISO container frame. Components of subunits are connected together by clamps 66p.
Each subunit may have level monitor systems 66g, 66v for sensing the level of material in the subunits, providing an indication of the amount of material therein. Each subunit has an opening 66s for personnel access with a corresponding cover 66z. Each subunit has a filtration system 66j for filtering air or other fluid exiting from the subunits.
In one particular embodiment of the system 60, a system 60a, each frame in each module is the size (or half size) of a standard ISO container or is the frame of an ISO container. Each module and/or subunit may have an industry standard access ladder located completely within a frame. These ladders can be aligned in adjacent modules so that personnel can ascend from the lowest module to the top of the system using these ladders. During transport to an assembly site, multiple modules may be stacked one on top of the other and connected with standard industry connectors, clamps, corners, and stacking cones for stability in both the vertical and the horizontal planes during storage or transport. Similarly such stability is achieved in the final assembled system. In the system 60a (and the system 60 and any subunit or module herein) any desired side opening of any subunit or module may be closed off with a removable panel or plate.
In the particular embodiment of system 60a, one particular subunit for the lowest base module 61 is made up of a plurality of standard ISO containers, e.g. such a container with a height of 9 feet, 6 and l/4th inches, a length of 53 feet, and a width of 8 feet 6 inches (as can be true for any of the subunits of any other layer or assembly or module of any system according to the present invention) . Such a module can be designed to support a maximum of eight or eight and a half such modules fully loaded with material having a bulk density of about or up to 1.75 gm/cm3 . In one aspect, nine such modules, when empty, may be stacked on each other. During service or storage and depending upon the prevailing ambient conditions, modules are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones. During service or storage and depending upon the prevailing ambient conditions, modules are secured in the horizontal plane by means of industry-standard horizontal clamp connectors and/or universal bridge clamps. Such modules may be fully enclosed on all sides with panels or plates except for the uppermost and lowermost planes. In certain aspects, the sides of the lowermost plane are enclosed and strengthened by panels or plates, e.g. but not limited to such panels with horizontal corrugations, horizontal when viewed as installed, in order to reduce the substrate point loading of the equipment while on-site and while in-service. Any unit, subunit, module or frame herein may be strengthened as desired with added structural members, e.g. beams, struts, crossmembers, etc. In certain aspects, a unit or module's lower-most bottom plane is interstitially stiffened utilizing structural steel members of, but not limited to, I-Beam, H-Beam, C-Channel, Rectangular hollow section, Square hollow section, T-Bars, and Flat bars, which can be, optionally, plated over with sheet steel plates of a suitable thickness, e.g., a half inch thick.
In the particular embodiment of system 60a, one particular subunit for the upper base module 62 is made up of a plurality of standard ISO containers. In one particular aspect such a subunit is a container with a height of 3'2"feet and a length of 53' or636", resulting in a module 61 feet wide and 3'2"feet high. A module like the module 62 can be designed to support a maximum of seven modules fully loaded with material having a bulk density of about or up to 1.75 gm/cm3 . In one aspect, nine (or eighteen half-height) such modules, when empty, may be stacked on each other. During service or storage and depending upon the prevailing ambient conditions, modules are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones. During service or storage and depending upon the prevailing ambient conditions, modules are secured in the horizontal plane by means of industry-standard horizontal clamp connectors and/or universal bridge clamps. The module may be fully enclosed on all sides but not on the uppermost and lowermost horizontal planes. Such a module can attach to the top of a module 61 so that the eight ISO multi-modal container corner castings are aligned and the modules are secured in the vertical plane by means of industry standard double vertical clamp connectors.
In the particular embodiment of system 60a, one particular subunit for the lower hopper module 63 is made up of a plurality of standard ISO containers. In one particular aspect, such a container has a height of 9' 6 W feet and a length of 53' or 636", resulting in a module 53' feet wide and 9' 6 W feet high. A module like the module 63 made of such subunits, can be designed to support a maxiimim of six full-height modules fully loaded with material having a bulk density of up to 1.75 gm/cm3 . The module has an inverted frustum-shaped hopper or containment membrane, suitably strengthened and supported by and within a standard ISO multi-modal container frame or frame of such overall dimensions; the uppermost horizontal plane of which is unenclosed, facilitating the free-flow of proppant from the adjacent upper hopper module. Free-flow of proppant from the upper hopper module is facilitated using an orifice at the lowermost point of the module. Such modules can be vertically stacked on top of one another to facilitate multi-modal transportation, handling, storage and delivery to site and during operations for the storage of proppant. While in transit on container liners and during storage as individual units, the module may be stacked empty up to nine full standard ISO units high. During service or storage and depending upon the prevailing ambient conditions, modules are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones. During service or or storage and depending upon the prevailing ambient conditions, conditions, modules are secured in the horizontal plane by means of industry-standard horizontal clamp connectors and/or universal bridge clamps.
In the particular embodiment of system 60a, one particular subunit for the intermediate storage module 64 is made up of a plurality of standard ISO containers. A module like the module 63 made of such subunits, can be designed to support a maximum of five full-height modules fully loaded with material having a bulk density of up to 1.75 gm/cm3 . The module in certain aspects has an inverted frustum-shaped member or containment membrane, suitably strengthened and supported by and within the confines of a standard ISO multi-modal container frame or frame of such overall dimensions; the uppermost horizontal plane and lowermost horizontal plane of which are unenclosed, thus facilitating the free-flow of proppant from the upper storage module into the module 64. The modules are designed to be vertically stacked on top of one another to facilitate multi-modal transportation, handling, storage and delivery to site and during operations for the storage of proppant.
In the particular embodiment of system 60a, one particular subunit for the top storage module 65 is made up of a plurality of standard ISO containers. This module is designed to support, as a total maximum, the sum of four full-height modules fully loaded (where appropriate) with material exhibiting a bulk density of about or up to 1.75 g/cm3. While in transit on container liners and during storage as individual units·, the modules may be stacked empty up to nine full standard ISO units high. During service or storage and depending upon the prevailing ambient conditions, units are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones. During service or storage and depending upon the prevailing ambient conditions, units are secured in the horizontal plane by means of industry-standard horizontal clamp connectors and/or universal bridge clamps. In certain aspects, proppant is loaded via penetrations on the tops and/or side faces of module 65. Such proppant loading is achieved using dense or dilute phase transfer. Other configurations are designed to be filled via openings in the upper-most horizontal face of module 63 by gravity.
In the particular embodiment of system 60a, one particular subunit for the top storage module 66 is made up of a plurality of standard ISO containers. The module in certain aspects has a rectangular-shaped member or containment membrane, suitably strengthened and supported by and within the confines of a standard ISO multi-modal container frame or a frame of such overall dimensions, the lowermost horizontal plane of which is unenclosed, thus facilitating the free-flow of proppant into the module 65. This module can provide an uppermost layer of the finally assembled system, afford a weatherproof cover, provide a means by which precipitation is collected and shed from the uppermost surface of the composite system, provide a means by which the composite system is charged with proppant materials and provide a means by which the egress of fugitive silica sand dust effected by the exhaust of air due to pneumatic dilute-phase or pneumatic dense-phase filling of the composite system is mitigated, e.g., using a filter, filter housing and/or associated HEPA filter cartridges. The modules are designed to be vertically stacked on top of one another to facilitate multi modal transportation, handling, storage and delivery to site and during operations for the storage of proppant . While in transit on container liners and during storage as individual units, the modules may be stacked empty up to nine full standard ISO units high. During service or storage and depending upon the prevailing ambient conditions, units are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones. During service or storage and depending upon the prevailing ambient conditions, units are secured in the horizontal plane by means of industry- standard horizontal clamp connectors and/or universal bridge clamps .
In certain aspects, such a system 60a is a multi-module modular proppant storage system with a composite support structure providing a multi-functional proppant delivery tunnel through the structure, one or multiple proppant storage containers for the storage and discharge of proppants utilized in hydraulic fracturing operations including, but not limited to silica sand, resin-coated silica sand, glass beads, ceramic beads, and sintered ceramic proppant of various grades exhibiting a bulk density of up to 1.75 g/cm3. The proppant storage container (s) are stacked vertically upon a composite base at an orientation which is normal to the orientation of the composite base. The lowermost storage container has a bottom hatch affixed to the bottom face of an inverted frustum-shaped container. The bottom hatch is movable between an open position and a closed position. Each of the lowermost material storage containers includes inclined surfaces and extending from the respective longitudinal and transverse vertical planes of the storage container thereof toward the bottom hatch. The lowermost storage container is fully open at its uppermost plane allowing the free-flow of stored proppant from vertically adjacent modules, thus forming a contiguous body of stored material within the structure. A joint (or joints) between vertically adjacent modules is sealed by means of a compression seal between two respective sealing faces. A shedding plate SP (see. Fig. 11D) attached to the internal surface of the lowermost longitudinal structural member of the vertically adjacent module in such a manner as to cause the level of the stored proppant material in way of the mating surfaces to remain below the level of the compression seal by forming an angle of repose of the stored material which prevents the stored material from overlying a compression seal and reduces or eliminates the incidence of material leakage. Such a plate may also promote solids movement and/or inhibit solids such as sand from migrating between adjacent modules or subunits at a point or area of connection. The compression seal(s) prevent the egress of fugitive material, e.g. silica sand dust, or other material fines from within the material confinement area to the ambient atmosphere and thus mitigates the incidence of injurious health effects, e.g. silicosis, in personnel. Successive vertically adjacent material material storage containers, each having a compression seal and and associated shedding plate, can be arranged in such a manner as to increase desired storage volume in height rather than in area footprint, increasing overall capacity, e.g. in one aspect up to a maximum of seven modules high. Variable, scalable configurations are therefore able to be assembled in vertical stacks of three, four, five, six and seven or more levels high, all on a suitably sized and configured modular composite base.
Fig. 11D shows the shedding plate SP mounted on a member of the module 66 with a bracket BR. An interface between part of the module 66 and part of the module 65 is sealed with a compression seal CN housed within aluminum rails Cl and C2 on an optional aluminum backing plate BL. The shedding plate inhibits solids build up in and around the interface of the two modules and inhibits solids flow in and around the seal CN (optionally the seal CN is omitted) . The shedding plate SP also inhibits the build up of solids in the area of the location of the bracket and the area beneath the bracket.
Figs. 12A - 12D show a liquid storage system 120 according to the present invention which has multiple storage modules 122 on a base 126 which are in fluid communication with a manifold 124. Each module 122 has a flow channel 122a through which fluid flows to a lower module or to the manifold 124. Fluid exits the manifold 124 through an exit port 124a. The system 120 rfiay be used for any suitable desired fluid, including, but not limited to, water, brine, calcium chloride solution, chemical mixtures, chemical solutions, non-corrosive oil field chemical solutions and suspensions, and solutions with a specific gravity of up to 1.15 g/cm3. Plates or panels 126 enclose sides of the system 120. These may be made of any suitable material, e.g. but not limited to, metal, plastic, fiberglass, fiber reinforced plastic or fiberglass, or composite material, corrugated or not, with a pattern of holes or perforations or not. Any desired level of modules may be used; e.g. five levels as shown in Fig. 12A or three levels as shown in the system 130, Fig. 13. The pressure of all the fluid in the system is transferred through the mass of water in the system to the bottom of the system. Any such system may include a liner 122v of suitable material lining the entire water storage space (as may be for any system herein) .
In one particular aspect, the modules 122 are the size of the frame of standard ISO container fifty three feet long; and the modules are stacked one on top of the other using standard clamps and cones.
As shown in Fig. 14A, the base 126 has a plurality of interconnected modules 126a each of which has a support frame 126b. In certain aspects, each module 126a is the frame of an ISO container or be a frame of the same dimensions as an ISO container. The manifold 124 is secured to a module 126a.
The manifold 124 has a frame 124c with compartments 124d, some of which have openings 124e which align with a corresponding opening 122a of a storage module above the manifold 124. All of the compartments 124d are intercommunicating and the manifold can receive all the water in all the storage modules above the manifold through the openings 124e. A butterfly valve 124g controls fluid flow from the exit port 124a. In certain particular aspects, the openings 124e and the exit port 124a are circular and are sixteen inches in diameter.
A system like that of Fig. 12A (and any herein) may have multiple manifolds, each with an inlet for feeding material into the system and with an outlet for expelling material. Any manifold for any system may be located as shown in Fig. 12A, manifold 124, at an edge of a system or, e.g., as shown with the manifold 124y, at an inner area of the system. Each level of a system may have its own manifold. Using such manifolds side-by- side systems like the system 120 can have their manifolds in fluid communication with each other for any desired flow regime between systems.
As shown in Fig. 12A, suitable apparatus PI within the system 120 provides an indication of fluid level and/or of internal hydrostatic pressure and/or of volume of liquid within the system 120
Figs. 15A - 15C illustrate a seal structure for sealing the interface between two openings of adjacent modules 122, as shown in Figs. 15B, 15C a top opening 122a of one module and a bottom opening 122m of an adjacent module, but usable for any two adjacent openings of any modules herein. As shown in Figs. 15B and 15C, a compression ring 122r is provided between the modules. This ring may be a separate member or, as shown, it may be formed integrally of a plate 122p used to close off a portion of the module. A compression seal ring 122s is disposed within the ring 122r and, as shown in Fig. 15C, sealingly abuts the lower surface of the upper module's plate 122tto seal the area around the opening 122m. Stacking cones 122v are used to stack the top module on the lower module.
As shown in Figs. 14D and 14E, access to a manifold 124 is provided through a port 124h which has a removable manway cover 124i over it. A system 124s with appropriate sensor parts within the manifold and/or on the manifold provides an indication of the level of fluid and the pressure of fluid in the system. A level display monitor provides a display of fluid level and, as desired, a display of hydrostatic pressure. Ball valves 124w permit fluid communication to pressure transducers 124t which provide a pressure indication.
Fig. 15D illustrates a seal 122p which can be used, suitable shaped and configured, as the seal 122s with corresponding spaced-apart seal rails 122n. Such a seal and rails may also be used with two adjacent parts of two adjacent subunits, units, or modules of any system herein to seal their interface.
In one aspect, a system 120a, which is one particular embodiment of the system 120, has a storage system support structure of standard ISO multi-modal container longitudinal and transverse dimensions and either standard or non-standard height (e.g. but not limited to half-height or quarter-height ) is · designed to support, as a total maximum, the sum of six full-height modules fully loaded (where appropriate) with material exhibiting a specific gravity of up to 1.15g/cm3. The system is designed to have modules stacked vertically, stacked on top of one another, to facilitate multi-modal transportation, handling, storage and delivery to a site and during operations for the storage and discharge of fresh water, brine, etc. While in transit on vehicles or on container ships and during storage as individual units, the modules may be stacked empty up to 27 units high (equivalent to 9 full-height standard ISO units) . During service or storage and depending upon the prevailing ambient conditions, modules are secured in the vertical plane by means of industry- standard double vertical clamp connectors, and/or industry- standard twist locks and/or industry-standard container stacking cones. During service or storage and depending upon the prevailing ambient conditions, modules are secured in the horizontal plane by means of industry-standard horizontal clamp connectors and/or universal bridge clamps. The module may be fully enclosed on all sides. It is advantageous in certain aspects to enclose the lowermost plane and to suitably strengthen it in order to reduce the substrate point loading of the equipment while on-site and especially while in-service.
In the system 120, the base support structure and the manifold are of standard ISO multi-modal container longitudinal and transverse dimensions and non-standard height. In certain aspects, the module is designed to support, as a total maximum, the sum of six full-height modules fully loaded (where appropriate) with liquid exhibiting a specific gravity of 'up to 1.15g/cm3. Such a module is designed to be vertically stacked on top of one another to facilitate multi-modal transportation, handling, storage and delivery to site and during operations for the storage and discharge of fresh water, brine etc. While in transit, e.g. on vehicles or on container ships and during storage as individual units, the modules may be stacked empty up to 27 units high (equivalent to 9 full-height standard ISO units) . During service or storage and depending upon the prevailing ambient conditions, modules are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones. During service or storage and depending upon the prevailing ambient conditions, modules are secured in the horizontal plane by means of industry-standard horizontal clamp connectors and/or universal bridge clamps.
Optionally and additionally two flanged openings, each of suitable , e.g. 16", diameter, are located within a recessed section of the module in way of the transverse vertical faces of the containment area to facilitate both charge and discharge of fresh water or brine solution; and two flanged openings, each of H" diameter and each coupled with a manually operated, ¾" ball valve to facilitate the separate attachment of two (2) units of hydrostatic pressure sensors and associated data collection and reporting hardware to facilitate the measurement of the volume of water contained within the fully assembled system. Additionally two flanged openings, each of 22' diameter to facilitate man-access into the internal volume of module are located in one of the longitudinal vertical planes. Closure of these openings is achieved via a suitable gasket and blind flange or similar structure.
Fluid may be pumped into the system through the exit port 124a of the manifold 124. The manifold facilitates both charge (addition) and discharge of water. In addition to the internal manifold system 124, and e.g. at the request of an end user, an external manifold (see e.g. Fig. 3) can be offered as an option.
The manifold 124 provides both vertical and horizontal integration of the water storage system, in effect a contiguous body of water to be delivered to the hydraulic fracturing equipment .
Delivery of the stored water is achieved by hydrostatic pressure and the rate of supply is controlled by means of an optimal number of remotely controlled or manually controlled valve (s). In certain aspects, a rate of supply of fluid achieved a system according to the present invention in excess of 3 times greater than that supplied on site by certain traditional on site water storage systems.
In the system 120a, a module 122 is designed to support, as a total maximum, the sum of five full-height modules fully loaded (where appropriate) with liquid exhibiting a specific gravity of up to 1.15g/cm3. The module is designed to be vertically stacked on top of one another to facilitate multi modal transportation, handling, storage and delivery to site and during operations for the storage and discharge of fresh water and / or brine. While in transit, e.g. on container liners, and during storage as individual units, the module may be stacked empty up to 9 units high. During service or storage and depending upon the prevailing ambient conditions, modules are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones. During service or storage and depending upon the prevailing ambient conditions, modules are secured in the horizontal plane by means of industry-standard horizontal clamp connectors and/or universal bridge clamps.
In the system 120a, he compression seals 122s between adjacent modules are made of a solid elastomeric polymer 0- ring restrained in the horizontal plane by one integral double ring or by two spaced-apart metallic, concentric retaining rings of appropriate configuration and dimensions for the chosen seal, e.g. rectangular section, attached to or welded to the horizontal bearing plate surrounding the previously noted aperture (s). The internal free edges of the rectangular section are chamfered by a suitable amount to ensure efficient sealing of the 0-ring with the retaining rings. The cross sectional diameter of the 0- ring, combined with the material of construction thereof is designed to provide a compression of between 25% and 40% in order to provide an effective seal. The offset of the two adjacent seal bearing plates is constant, being described and dependent upon the spacing of the vertically stacked modules, the contact between respective modules being made at the incorporated container corner castings and the associated container stacking cones utilized to provide transverse stability to the assembled modules.
In certain aspects, a lowermost horizontal plane of a module is inclined at an angle of between +1% and +2.5% from the horizontal to promote and insure drainage of the liquid contents towards the opening between adjacent modules. Similarly, the uppermost horizontal plane of a module is inclined at an angle of between -1% and -2.5% from the horizontal to ensure effective venting of air from the module towards the opening between adjacent modules during charging of the liquid contents.
A ladder of standard industrial design is incorporated into a module (and each module or subunit if desired) to provide access to vertically stacked adjacent modules. The ladder is fully within the confines of the standard ISO container dimension limits, but is located externally to the confines of the water containment area. In certain aspects there is only one subunit or module with a ladder or each subunit and module may have a ladder, either "for interior access or for access to a vertically adjacent module.
A topmost module (not shown) of the system 120a may have no top opening. It may have one or more manholes with removable closures for accessing the system interior. Such a module can store liquid of a specific gravity of up to 1.15g/cm3 as a single module and for transportation and storage purposes may be stacked 9-high while empty. Such a module serves as a feed-water tank for the system 120a and is designed to receive liquid from multiple, e.g. two to seven units of vacuum trailers simultaneously. Such a feed water tank is located as desired; and can be vertically stacked on top of one another to facilitate multi-modal transportation, handling, storage and delivery to a site. While in transit, e.g. on container liners, and during storage as individual units, the module may be stacked empty up to nine units high. During storage and depending upon the prevailing ambient conditions, such modules are secured in the vertical plane by means of industry-standard double vertical clamp connectors, and/or industry-standard twist locks and/or industry-standard container stacking cones. In certain aspects, such a module is a box-like structure, fully enclosed on each longitudinal and transverse vertical planes and both horizontal planes and is incorporated into an ISO multi-modal container frame of standard dimensions, suitably strengthened or a frame of standard ISO container dimensions. In certain aspects, such a module (not shown) has these features:
At one end of the module there exists a 3" or 4" fill pipe with threaded termination. Along each of the longitudinal vertical planes, there exist three 3" or 4" fill pipes with threaded terminations; one of which is located at the center of the vertical longitudinal plane and the others being located towards the ends of the module at a suitable spacing to allow the placement of three vacuum trucks to facilitate simultaneous filling of other modules. In way of the transverse vertical plane opposite to that in which there exists a fill pipe, is a recess to allow the incorporation of a 16" flanged discharge pipe thro.ugh which liquid is discharged by a separate pumping system^ 3" ball valve located close to the lowermost horizontal plane of the liquid containment areas to facilitate draining of the module following use and prior to storage of the module; a sight-glass to indicate visually the level of liquid contained within the module and a standard industrial ladder to provide access to the uppermost horizontal plane of the module and an industry standard quick opening manway.
Three square manhole accesses, with covers, positioned one in each location along the intersection of the longitudinal and transverse centerlines, at one end of the longitudinal centerline and diametrically opposite at the end of the longitudinal centerline.
Any module or part thereof of any system according to the present invention can have panels or plates that are themselves made of insulating material and/or additional insulation material and/or members may be added; e.g., but not limited to, for use in extremely cold conditions or in extremely hot conditions .
In certain aspects, the manifold 124 of the system has six openings in the uppermost horizontal face of the containment area which correspond to single openings in each of the lowermost water containment modules. Variable, scalable configurations are able to be assembled in vertical stacks of three, four, five and six or more levels high, excluding the composite base to provide the desired storage capacity of each composite system. The water containment modules are stacked vertically adjacent on the base and orientated normal to the composite base. The openings are fitted with retaining rings and an elastomeric O-ring of solid cross-section and which exhibits a suitable degree of compression, thus facilitating a waterproof seal and preventing leakage of the contained liquid material from within the modules. Storage modules are located vertically adjacent of the base using industry-standard container stacking cones and secured in the horizontal orientation by using industry-standard horizontal clamping bridges. Six sets of vertically orientated stacks are assembled horizontally adjacent to one another. Such an arrangement ensures that all liquid contained in the storage units exists as a contiguous volume, joined via the manifold. Additionally, the manifold module has at each end thereof, one flanged aperture of suitable diameter to ensure free-flow of liquids to be charged and discharged from the assembled storage system into and out of the system. Such openings are designed to be fitted with a closing device, e.g. a valve of suitable design so as to enable an operator or an automatic system to rapidly open and close the valve. Additionally, the manifold module can have two flanged or threaded openings located adjacent to each other, separated by a suitable distance so as to allow the fitting of two units of hydrostatic pressure sensors and associated data processing and reporting equipment. Such equipment can indicate the level of liquid contained within the assembled storage system in real-time.
In certain aspects, such storage systems have materials contained within ISO standard-sized receptacles which provides: ease of handling using containers/equipment that is/are modular
ease of delivery via standardized vehicular equipment ease of storage
intermodal relocation
amounts of material available on-site without the need to rely upon known delivery methods and vehicles and the inherent problems associated with such systems are scalable and available in numerous configurations suitable for a wide range of volumes of material storage materials and solutions .
Safety of a site is improved using certain embodiments of the present invention, including:
- reduction of site clutter, reducing equipment operative injuries
deliveries of materials and equipment may be made at opportune times to ensure that minimal personnel are present on site during equipment handling.
The advent of multi-well sites requires ever- increasing amounts of materials to be delivered and stored near or on site. Certain systems according to the present invention can provide raw materials and fluids for fracturing, including "zipper" fracturing procedures, currently being employed, and such systems provide scalability for larger installations, including multi-well sites, and for possible future technological advancement, for fracturing multiple wells and for fracturing multiple wells simultaneously in large numbers.
Certain systems according to the present invention reduce or eliminate the need for trucks, trailers, vehicles, containers, and specialized vehicular transportation methods and delivery equipment, including single axle "frac" tanks which can cause significant damage to public roads and highways. Certain systems according to the present invention reduces wear-and-tear on the public roadways and highways since there is an increase in the number of trailer axles on standard ISO container trailers (rather than single axle equipment), resulting in lower road loading and thus reducing road damage. Fig. 16A shows a system 160 according to the present invention which has multiple proppant (or solids) storage systems 161 (any such suitable system according to the present invention, including, but not limited to, those of Figs. 2A-11A) and a central fluid system 162 (any such suitable system according to the present invention described herein) .
A liner 162a, made e.g. of elastomeric polymer film, lines the central fluid system 162. Solids (and/or a frac fluid with liquid and solids) from each system 161 are pumped in associated lines 162b from each of the eight systems 161 to wellheads 162c. Solids and/or liquids for recharging the systems 161 are delivered to the systems 161, which may be available on site, e.g. solids and/or liquid separated on site from a slurry or mixture on site; and/or solids and/or liquids provided by items 162d, e.g. vehicles, trains or containers, which can be moved under and/or within the systems 161. Optionally, the items 162d are blender systems for blending solids and liquids, e.g. water and sand.
Optionally, as may be true for any system herein, there is no liner and the system 162 includes structural members 162s (eight shown in Fig.l6A; any suitable desired number of these within the scope of the present invention) which are connected together so that they form a sealed container for containing material, mixtures, slurries, fluid component ( s ) , and/or fluids. Optionally each line 162b has a pump for pumping material and/or fluid from the systems 161 to the wellheads 162c (as may any line to any wellhead in any system herein) . The wellheads 162c represent any suitable known wellheads, including but not limited to, standard wellheads, e.g. "Christmas tree" wellheads. The structural members 162s may be solid or hollow, with or without an internal skeletal or supporting structure or support beam(s).
Fig. 16B shows a system 163 according to the present invention which has multiple proppant (or solids) storage systems 164, with six pairs of two storage systems side-by-side (any such suitable system according to the present invention, including, but not limited to, those of Figs. 2A-11A) and a central fluid system 165 (any such suitable system according to the present invention described herein). A liner 165s (e.g. like the liner in Fig. 16A) lines the central fluid system 165.
Solids and/or liquids and/or fluids from each system 164 are pumped in associated lines 164b (several shown; there are lines to each wellhead or portable lines usable for each wellhead) from each of the systems 164 to wellheads 164c (with a pump for each line or pumps for pumping fluids for all lines, pumps not shown) . Solids and/or liquids and/or fluids for recharging the systems 164 are separated on site from slurries or mixtures provided on site and/or are delivered to the systems 164 by vehicles, trains or containers 164d which can be moved under and/or within the systems 164.
Fig. 16C shows a system 166 according to the present invention which has multiple proppant (or solids) storage systems 167, with six trios of three storage systems side-by- side (any such suitable system according to the present invention, including, but not limited to, those of Figs. 2A-11A) and a central fluid system 168 (any such suitable system according to the present invention described herein) . ] A liner 168s lines the central fluid system 168. Solids and/or liquids and/or fluids from each system 167 are pumped in associated lines 167b from each of the eight systems 167 to wellheads 167c. Solids and/or liquids and/or fluids for recharging the systems 167 are separated from slurries and/or mixtures provided on site, or they are delivered to the systems 167 by vehicles, trains or containers 167d which can be moved under and/or within the systems 167. In any of the systems of Figs. 16A - 16C, and in any suitable system according to the present invention, the vehicles etc. may be loaded with solids from the solids systems and/or liquids may be provided by any system according to the present invention. There may be lines 167b for each wellhead 167c; and each line may have its own dedicated pump.
Fig. 17 presents a schematic of a system 170 for a method for providing frac fluid to a well or multiple wells using a solids system 171 according to the present invention (any suitable solids system disclosed herein) and a liquids system 172 according to the present invention (any suitable liquids system disclosed herein.) At an injection point 173 liquids and solids are provided from one or more sources and then with pumps PM and/or pumps PU a mixture from point 174, e.g. a slurry, of liquid and solids is fed to further processing apparatus FP which may include apparatus for washing, dewatering, and/or grading. The apparatus FP produces dry solids DS, e.g. dry proppants or dry sand, which is pumped to the proppant system 171. The apparatus FP produces water that is supplied to a mixture point 175, and/or water that is supplied to the system 171 and/or to a water recirculation pipeline for transmission back to the point 174. The system 171 feed proppant to the mixture point 175 from which a frac fluid with proppants is pumped to a blender and/or chemical injector for selective addition of other additives, if desired, and for blending. Finished frac fluid is then pumped to a well or to multiple wells.
The mixture pumped from the point 174 may be a slurry of any desired % constituents; e.g., but not limited to, a slurry of 70% to 80% sand, the balance water; or a slurry of 30% to 38% sand, the balance water - by weight. Optionally the pumps PM are positive displacement pumps and the pumps PU are centrifugal pumps.
As is true for any system herein using multiple solids modules, one particular module may have one material and another module may have another material; e.g. a single system can provide sand from one module, ceramic proppants from another module, and solid additives from another module.
Fig. 18A shows a solids handling/storage, feed system 180 according to the present invention which has a support 181 which defines two access spaces 182a and 182b above which are positioned multiple controlled solids outlets 183 (there are six outlets 183) of solids containers 184. Each container 184 has sloped walls to facilitate solids movement. The containers 184 are supported by support frames 184f.
Fig. 18B shows a solids handling/storage, feed system 185 according to the present invention which has a support 186 above which are positioned multiple controlled solids outlets 188 (there are eight outlets 187) of solids containers 187. Each container 187 has sloped walls sloping to two outlets 188 to facilitate solids movement. The containers 188 are supported by support frames 189.
It is within the scope of the present invention to leave any structure or system according to the present invention in place once it has been used in all the fracking jobs in a particular area for re-use in any number of beneficial ways. For example, a water storage system according to any embodiment of the present invention which is capapble of holding hundreds of thousands or millions of gallons of water can then be used as part of a seawater desalination plant, as a water storage facility for a park or small town, or as a water storage facility for a crop irrigation irrigation system. Optionally a liquid storage system according to the present invention is used as a liquids storage pit or as a mud pit for rig operations.
Fig. 19A shows a system 190 according to the present invention which has a solids system 191 according to the present invention (e.g., but not limited to, like the systems 60, 180 or 185) and two fluid storage systems 192
(e.g. like any such suitable systems herein according to the present invention) . The system 190 provides solids (e.g. but not limited to proppants) and fluid (e.g. but not limited to water) to an injection manifold 193 (e.g. a high pressure manifold, sometimes called a "bullet" or a "rocket") from which via lines 194 (lines for each wellhead; or movable lines useful with each wellhead) a fluid (e.g. but not limited to a frac fluid) is transmitted to wellheads 195. Pump systems 196 (eight shown) on vehicles 196a pump the materials from the systems 191 and 192, to the manifold 193, and to the wellheads 195.
A truck-mounted blending system TK blends fluid components; e.g. in certain aspects, water from the systems 192 is blended with proppants from the systems 191.
Fig. 19B illustrates a system 190a, similar to the system 190 (like numerals indicate like parts), but which has eliminated the pumping systems 196 and the manifold 193 and replaced them with systems 199 according to the present invention which provide for the pumping of material, liquid and/or fluid and include pumping apparatus and, if needed, power apparatus, that accomplishes the functions of the systems 193 and 196. With more than one system 199, a single wellhead may receive fluids from more than one system 199, in series or in parallel .
Fig. 19C illustrates that a system as in Fig. 19A or 19B, or any suitable system herein, can be scaled up as desired to provide any desired level or amount of solids storage and processing and/or any desired amount of fluid storage and processing. A system 190c has a solids system 190d, e.g. but not limited to a system 120, and four systems 192.
It is within the scope of the present invention to locate a system according to the present invention at or near a rig site, including rig sites that may be relatively remote. This includes systems on barges, ships, or floating rigs for offshore operations. Fig. 20 shows a system 163 located in a remote area RA · which is supplied via a pipeline 201 and is accessed via a road 202. Optionally the system 163 can supply solids and/or liquid and/or fluid(s) via the pipeline 201 to other sites. Any suitable system herein may be used instead of the system 163. Also, any such system may handle and provide recovered water at the site of the system 163 (in Fig. 20) or at another site. Multiple pipelines and/or multiple roads may also be provided.
It is within the scope of the present invention to provide systems with components which can be transported by truck, trailer, barge, pipeline, ship, or by train. With respect to system components that hold solids or liquids, the components can be transported empty to a site where they are filled; or they can be transported full of the solids or the liquids that are to be used in an operation. In certain aspects, the components that contain solids or liquids are standard ISO containers of a chosen standard size. Fig. 21A illustrates a train 210 with multiple cars 211. Some of the cars (or all) may have stacked ISO containers 212 which are components of systems according to the present invention. These containers 212 may be components of a solids storage system according to the present invention or they may be components of a liquids storage system according to the present invention, or both. The train 210 may be transporting empty or full containers to or from a site of use of the solids and/or liquids, and/or to or form a location of a system according to the present invention. Any suitable desired containers and/or rail cars may be used, including, but not limited to, selected ISO containers of desired size and dimensions.
It is within the scope of the present invention to have a rail line or a track spur adjacent or passing through a system according to the present invention so that rail cars and/or containers may be accessed for loading or unloading near or within a system according to the present invention. In certain aspects a rail line is located so that a train (entire train or part thereof) may pass through a system according to the present invention. Fig. 21B shows a system 216 according to the present invention for storing and processing solids, e.g. but not limited to a system like the system 120 described above. Rail tracks 217 of a rail line pass through and beneath the system 216 so that a train 218 with cars) 219 can move under and within the system 216 for loading and/or unloading of the cars
219. Although not shown, such an arrangement and design are also useful with certain liguid storage systems of the present invention with space provided under the system components for train tracks and passage of a train. Optionally the system 216 (or any system herein) includes a pit 216a or tank for receiving material from the rail cars and/or for storage.
Fig. 22 illustrates a container ship 220 on whose deck are stacked ISO containers 222 which are components of systems according to the present invention. These containers 222 may be components of a solids storage system according to the present invention or they may be components of a liquids storage system according to the present invention, or both. The ship 220 may be transporting empty or full containers to or from a site of use of the solids and/or liquids. Typical crane apparatus 224 is used to load and unload the containers 222 to and from the ship
220.
Figs. 23A and 23B show a system 230 according to the present invention which has a plurality of container modules 232 supported in a structure 234. In certain aspects, one such modular container is a standard ISO container or is of the dimensions of a standard ISO container. In certain aspects, two, three, four or more of the modular containers are a standard ISO container or are of the dimensions of a standard ISO container. In certain aspects, structural members of the ISO containers provide structural members of the system 230. Each container module 232 has a top opening 232a for material loading and a bottom outlet 232b for material exit. Via a manifold 236 all material in all container modules is flowable from the system 230. The manifold 236 may have appropriate valves, seals, sensors, and connections (e.g. but not limited to as any shown or described herein) . The system 230 may be used for the storage and provision of liquids, solids, and/or fluids (fluids including, but not limited to, fluids with solids therein) .
In one particular aspect, the system 230 stores frac fluid with water and proppants (e.g. sand or ceramics). In certain aspects, such frac fluid in "well-ready" and can be pumped from the system 230 into a well. In other aspects, the additional water is added to the frac fluid and then it is pumped into a well. Any suitable pipeline, pipe or other conduit may be used between the system 230 (of any desired length) between the system 230 and the well. Optionally, either directly into the system 230 or at any point before the frac fluid arrives at a downhole fraccing location, additional additives for facilitating fraccing and/or fluid recovery may be added to the frac fluid. At any point either within the system 230 or between the system 230 and the -well, any suitable pump system (s) and apparatuses may be used to pump material from the system 230 to the well.
Figs. 24A and 24B show a system 240 according to the present invention which has a plurality of container modules 242 supported in a structure 244. In certain aspects, one such modular container is a standard ISO container or is of the dimensions of a standard ISO container. In certain aspects, two, three, four or more of the modular containers are a standard ISO container or are of the dimensions of a standard ISO container. In certain aspects, structural members of the ISO containers provide structural members of the system 240. Each container module 242 has a top opening :242a for material loading and a bottom outlet 242b for material exit. Via a manifold 236 (liked that of Fig. 23A) all material in all container modules is flowable from the system 240. The container modules 242 may have inclined walls both at the bottom and at the top, as shown, to facilitate fluid flow.
In one particular aspect, the system 240 stores frac fluid with water and proppants (e.g. sand or ceramics). In certain aspects, such frac fluid is "well-ready" and can be pumped from the system 240 into a well. In other aspects, the additional water is added to the frac fluid and then it is pumped into a well. Any suitable pipeline, pipe or other conduit may be used between the system 240 (of any desired length) between the system 240 and the well. Optionally, either directly into the system 240 or at any point before the frac fluid arrives at a downhole fraccing location, additional additives for facilitating fraccing and/or fluid recovery may be added to the frac fluid. At any point either within the system 240 or between the system 240 and the well, any suitable pump system (s) and apparatuses may be used to pump material from the system 240 to the well.
Figs. 25A and 25B show a manifold 236 which may have any of the valves, parts, connections, sensors, and/or piping of any manifold shown or described herein. In certain aspects, the manifold 236 has a plurality of openings 236a, one each corresponding to bottom outlets of containers supported above the manifold for receiving material flowing for the containers. The openings 236a communicate with piping 236b which provides for the flow of the material to an outlet 236c via outlet pipe 236d which is in fluid communication with the piping 236b.
Certain typical frac fluid provision systems include silos and containers for holding materials used in fraccing operations and roads to and from them for trucks to bring material to the silos, etc. and to move the materials from the silos, etc. to the sites of wells. In certain aspects these can include one or some of load-out silos, shale play transload silos (long range and short range) , local load out silos, rail load out silos, sand (or resin coating and/or or other solids) storage, and the roadways interconnecting these for truck access. It is within the scope of the present invention, using pipelines and systems according to the present invention, to eliminate some or all of the roadways required for some fraccing operations; and to use storage and fluid systems according to the present invention instead of some or all of the silos, etc. of some known systems. In such systems according to the present invention the need for trucking of materials can be significantly reduced, or in some cases, eliminated.
As shown in Fig. 26, in* a system 260 according to the present invention, frac fluid (with full moisture content or with partial moisture content) may be provided to any of a number of well sites ("TO WELL SITE") via a pipeline or pipelines 262a - 262i. In one particular example of a system
260,. frac fluid which includes water and sand with a known moisture content, e.g. a moisture content which permits pumping of the fluid, is pumped from a system 264a or 264b to a well site. It is to be understood that the pipelines in Fig. 26 include suitable and appropriate valves, connections, pumps, piping, sensors, and controls to effect the pumping of fluid to the wellsites, and, optionally, mixing or blending apparatus and/or additive injection or introduction apparatus. Optionally the moisture content is such that no additional water is added before pumping into a well; or as shown, additional fluid (e.g. but not limited to, water) is added to the fluid from the systems 264a and/or 264b, using systems 265 according to the present invention, to produce a finalized frac fluid for introduction into a wellbore. In certain aspects, varying concentrations of sand suspended in an aqueous medium are achieved by using a "flotation cell" into which compressed air is introduced into a mixture or a slurry at a pre-determined and calibrated rate and volume. By varying the rate of introduction of the compressed air into the system, a desired aqueous medium is achieved. In certain aspects, the systems 265 are any suitable known systems herein for the storage of and provision of fluid for fraccing.
It is within the scope of the present invention for the system 260 to include one or more blender apparatuses 266 used in conjunction with the material flowing in a pipeline to further blend the material in the pipeline; and/or for such blender apparatuses to add material, proppants and/or additives to the flow in a pipeline, blend the materials, etc. and re-introduce them back into the pipeline .
As shown with the railcar 269a, it is within the scope of the present invention to provide sand from, e.g., a frac sand source such as, but not limited to, a frac sand mine FSM with rail access, directly for a pipeline (e.g. the pipeline 262f) . Optionally, the rail line and rail cars provide sand (or other proppants or additives) to the system 264a. The system 264a can include one system for providing frac fluid or frac fluid needing additional moisture, or it can includes multiple systems in series or parallel (e.g. as the system 264a as shown with two fluid provision systems x and y) . Rail may also be used to provide sand (or other solids) to any system herein, e.g. as shown by the railcar 269b providing sand from the frac sand mine FSM to the system 264b and/or 264c. Also, sand e.g. from the system 264c may be provided to the system 264b as needed. Optionally, as shown with the pipelines 262b and 262h, multiple storage systems can supply a single well .
Any pipeline in any system herein may be used to pump recovered water, recovered sand, and/or any flowback fluid from a well back to any of the systems of Fig. 26.
Any fluid produced from a well and/or water and/or any hydrocarbons, natural gas liquids ("NGLs"), and/or oil and/or flare gas may be fed to a plant 268 at any desired location through any chosen pipeline for procession and/or further transmission. This includes, in certain aspects, separation systems and apparatuses in the plant 268 to separate a chosen fluid, water, flare gas, NGL, etc. A separated fluid, etc. can be fed, e.g. via pipeline, to another site and/or to a rail line and to suitable cars on the rail line (e.g. the rail line with the car 269a) . In one aspect, instead of flaring flare gas at a wellsite or at a processing facility, the flare gas is collected (either chemically or physically) and/or processed and/or separated and transferred by rail and/or by pipeline.
It is within the scope of the present invention for a system according to the present invention to serve multiple wellheads at one site or at multiple sites; in one aspect, requiring minimal trucking of materials and fluids. The system 260 is shown as servicing five well sites. A system 270, Fig. 27, is like the system 260 (like numerals indicate like parts) and it includes pipeline 262a, system 264a, items 265, 262c,
262d, and 262e (collectively referred to as system 270s. Via pipelines 270a and 270b, the system 264a can service additional wellheads in systems 270c and 270d (like the system 270s) . It is within the scope of the present invention for a system according to the present invention e.g., but not limited to, as shown in Figs. 26 and 27 to service any desired number of well, with suitable pipelines and/or rail access. In a variety of known systems, materials (e.g. solids and/or liquids and/or fluids with solids therein) are transported by truck/trailer/tank and are stored on or off site in suitable tanks, containers, or silos. Using certain systems according to the present invention, some, most or all of these tanks, etc. may be eliminated; and/or some, most or all of the previously-required trucking is eliminated. ("Fluids" herein includes fluids with solids therein) .
It is within the scope of the present invention to flow air or other gas, etc. to and through solids, e.g. proppants, in a hopper, etc. e.g. a container; or to affect the solids by flowing air, etc. to contact a surface of a member or item on the other side of which are the solids. Affecting the solids can include dehumidifying them, heating them, or cooling them. Figs. 28A-28C show a system 280 according to the present invention which includes a solids storage container system 281, e.g. for proppants, e.g. for sand. The interior of the container includes sloping walls 281a, 281b and side walls 281c. The container has ends 280k. Openings 281d allow air flow from beneath the walls 281a, 281b up into the sand within the container. Air at ambient temperature may flow through openings 281e, 281f to the openings 281d. Optionally, a fan 281g positioned at each opening 281e, 281f pulls air from outside the container 281 into space within the container below the walls 281a, 281b. Optional apparatuses 281h may dehumidify, heat, or cool the air pulled into the container by the fans 281g; and/or supply a gas or vapor, or combination thereof, other than air or in addition to air; and/or they may provide a treatment to proppants including, but but not limited to, any known treatment for any proppant . Optionally, the openings 281a, 281b are sized, shaped, located and configured so that dams 280j of solids build up over them, which allow air or gas flow. Optionally, these openings are covered with suitable screen or mesh to facilitate dam formation. Optionally, a fan or fans 280i are provided for the container to facilitate exhaust of air or gas from within the container. Arrows indicate the path of air flow into and out of the container 281.
Figs. 29A and 29B show a container structure 290 which has a beam support network 291 including beam support members 291a - 291d on the structure's exterior and beam support members 291e - 291g interconnected within the structure 290. Exterior walls 292a - 292e define parts of sides of the structure 290 and bottom walls 293a, 293b along with outlet walls 294a, 294b define part of the bottom of the structure. Such a structure may have any desired number of outlets for the exit of solids therefrom. As shown, the structure 290 has six outlets 295 (three clearly visible in Fig. 29B) . Optionally, an. enclosed ladder structure 296 within a corner 297 of the structure 290 provides access to various levels of the structure 290. Such a structure can store, e.g., sand which is all substantially the same; or it can store sands that are different, e.g., in the structure 290 from one to six different grades of sand.
In certain aspects, the present invention provides a bucket elevator for loading solids into a container and the main parts of the system for receiving, holding, and ejecting the solids into the container are sized and configured so that they fit within a standard ISO container and are then easily transportable to a site for use. Figs. 30A - 30C show a elevator system 300 according to the present invention within a standard ISO container framework FW. A subsystem 301 provides the functions of loading solids into buckets 303 (shown schematically with dotted lines) of a moving subsystem 302 and of powering movement of the subsystem 302. As shown in Figs. 30A - 30B, the subsystem 302 has been raised by the subsystem 301. The framework FW of the ISO container may be used at a site as a support for the bucket elevator system. Optionally, a stair system 304 (shown in dotted lines in Fig. 30C) is provided for personnel to access the elevator and/or to access different levels of a container which can be loaded using the elevator. Such an elevator system may be positioned within any suitable container according to the present invention; or it may be disposed outside the container, with appropriate connections, opening, conduits, and piping to move solids from the elevator's buckets into the container. Such an elevator system can provide solids into a container at any selected level of multiple levels of the container and/or at multiple levels of solids already within the container. For structures according to the present invention which include a plurality of individual containers side-by-side, each may have its own dedicated elevator system or one system can be movable to provide solids to each individual container.
Fig. 31A shows a system 310 according to the present invention which has a container 312, e.g. but not limited to a hopper for solid proppants, with solids 314 therein. A movement enhancing system 316 is in communication with the container 312 via suitable openings to enhance the flow of solids from the container 312 and/or to enhance the movement of the solids from
*
the container to another structure, e.g., but not limited to, into another container, into a flow line, into a pipeline, into a truck-trailer, or_into a railcar.
Fig. 31B shows a system 3ll according to the present invention which has containers 313, e.g. but not limited to hoppers for solid proppants, supported by a support structure
319. Each container has solids 315 therein. Associated with each container 311 is a movement enhancing system 317 in communication with a corresponding container 311 via suitable openings to enhance the flow of solids from the containers 311 and/or to enhance the movement of the solids from the containers to another structure, e.g., but not limited to, into another container, into a flow line, into a pipeline, into a truck trailer, or into a railcar. Optionally, the systems 317 are within the containers 311 within the solids 315, as shown by the dotted lines in Fig. 31B.
f
Figs. 32A and 32B shows a system 320 according to the present in invention with a support frame 322 supporting a solids container 324, e.g. but not limited to a· hoppers for solid proppants, configured for solids exit from the bottom of the container. Solids are introduced into the container via top opening 326 and exit from a bottom opening 327 into a movement enhancing system 328. As is true for · other suitable embodiments of the present invention, the container 324 may be a container made to meet ISO requirements, and/or it may be an appropriate ISO shipping container. In one particular aspect, the container 324 is 8 feet long, 7.2 feet wide, and 7.6 feet tall.
Fig. 33 shows a system 330 according to the present invention which has multiple containers 334 (not all shown), e.g., but not limited to hoppers for solid proppants, each with a lower solids movement enhancing system 338. A support structure 332 supports the containers 334 and the systems 338. The systems 338 are encompassed completely by the structure 332; but they may have parts that project outside the structure.
Fig. 34 shows a container ship SP with multiple containers 344 stacked therein so that upper containers are in communication with lower containers for the flow of solids from the uppermost container down to the lowermost container. Each of the lowermost containers has an associated solids movement enhancing system 348.
In certain known oceangoing vessels, up to 1200 tons of solids, e.g. sand, is stored onboard. With an appropriate ship, using storage containers (e.g. two) with multiple compartments according to the present invention, 150,000 tons of such solids will be able to be stored;
e.g., but not limited to, using two of the container systems, appropriately sized, shown in Fig. 6A, Fig. 12A,
Fig. 24A, or Fig. 29A with one or with multiple movement enhancing systems, e.g. but not limited to, as shown in Figs. 31B or Fig. 33. Figs. 35A and 35B show a railcar RC with lower solids movement enhancing systems 350 for facilitating the removal of solids from the railcar.
In certain embodiments of the present invention, damp sand is loaded into a railcar according to the present invention. Such loading of damp sand reduces or eliminates fugitive dust, e.g. but not limited to, fugitive silica dust. Offloading of the sand is facilitated by using one or more movement enhancing systems according to the present invention with no fugitive duct .
In certain particular aspects the solids movement enhancing systems in the systems of Figs. 31A - 35A are a desander- accumulator system such as that disclosed in U.S. Patent 6, 119, 779.
It is within the scope of the present invention to provide a system for facilitating the unloading of sand or similar material from a transport vehicle, railcar, tank, container or vessel (all collectively referred to as "container, etc."). In certain aspects such a system includes a fluidizing unit into which liquid (e.g. but not limited to, water) is introduced to mix with material (e.g. but not limited to, sand) being unloaded to form a material/liquid slurry which flows into another container, etc.
In certain aspects, such systems for facilitating unloading include a container, etc. with an opening or openings through which unloaded material flows down from an upper container, etc. into a lower container, etc. Associated with the opening (s) is a fluidizing unit or apparatus, or units, which receives the material being unloaded (from an upper container, etc.). Liquid, e.g. water, flowing into the fluidizing unit(s) produces a stream flowing down into the container, etc. in the form of material/liquid slurry.
Optionally, the material/liquid slurry from the lower container, etc. is flowed to or is pumped to: another container; a pipeline; a railcar; another vessel; a tank; to other storage or processing equipment; or to any container, etc. disclosed in any embodiment or system herein according to the present invention. In certain aspects, the slurry from the lower container is flowed to or pumped to a manifold from which the slurry can be directed as desired to a single line or simultaneously to multiple lines as selected.
In certain aspects, water is supplied to fluidizing unit(s) and the unit is designed, sized, structured, and configured so that swirling action or a vortex is created within the unit(s) to enhance slurry formation and/or homogeneity. Such motion or action may facilitate flow of material from an upper container to a lower container.
In certain aspects, the upper container (e.g. but not limited to, a railcar containing sand) has multiple lower discharge openings that can be opened individually, sequentially, or all at once simultaneously; and/or a lower container of a system according to the present invention may have multiple top openings for receiving material from one or all of an upper container's discharge openings; in one aspect, the lower container receives material simultaneously from all of an upper container' s discharge openings . The system for facilitating material unloading can be within a support structure which supports a container, etc. (e.g. a railcar) above the system; e.g. an elevated support onto which a railcar is moved or placed, with the system according to the present invention for facilitating unloading beneath the railcar, permanently installed or moved into place for unloading of the railcar. Optionally, the system for facilitating unloading is below grade (e.g. below the ground level of the level of a rail line) so that the railcar simply has to be brought to stop over the system for unloading. In one particular aspect, a system SST, or systems, according to the present invention (Fig. 21B) is below grade and has fluidizing unit(s) FDT so that material (e.g. but not limited to, sand) can be unloaded from the cars 219. In one aspect, after the cars 219 are unloaded, they are advanced and then filled with solids from the system 216.
Fig. 36A shows a system 360 according to the present invention for facilitating unloading of material ML from a railcar RL. Material flows from the railcar RL (arrow AR) down into and through an opening OP in a container CT of a system SSM according to the present invention. The material ML is initially received by a fluidizing unit FT into which liguid (e.g. but not limited to, water) is pumped (arrow AO) by a pump system PT . The pump system may be located as desired, below grade, above grade, in the container, on the container, in the railcar, or on the railcar. The unit FT produces a slurry with material (arrow AW) .
Fig. 36B shows a system 361 including an unloading system and a loaded railcar according to the present invention the system including apparatus and structures for facilitating unloading of material MM from a railcar RR. Material flows from the railcar RR (arrows AA) down into and through reception structures RC, through fluidizing units FZ into a container CN according to the present invention (and which is, e.g., like any container herein, including but not limited to the container CT of Fig. 36A in any of its forms) . Liquid (e.g. but not limited to, water) is pumped (arrows AS) by a pump system PP. The pump system may be located as desired, below grade, above grade, in the container, on the container, in the railcar, or on the railcar. The unit FT produces a slurry with material (arrows AB) . The railcar RR may be at grade and the container CN below grade; and/or the railcar RR may be on a support above the container CN (with the container at, above, or below grade) .
Optionally, the system and its components are designed and operated so that little or no liquid flows back into the railcar RL. Optionally evacuation apparatus ET removes material from the container CT for storage, for further processing, for transfer, for transport, or for transmission (e.g. but not limited to, into a conduit op pipeline) .
Optionally, a container may have multiple bottom openings through which material can be discharged for unloading; for example, the railcar RL may have multiple openings OS, shown in dotted lines in Fig. 36; and/or the container CT can have multiple systems SST, shown in dotted lines in Fig. 36, like the system SSM for receiving discharged material (or the systems SST may be like any systems herein for unloading a railcar) . The container CT may be of any dimensions, e.g. of any diameter or of any height (as shown by the curved line at the bottom of the container in Fig. 36) . Such systems for facilitating material unloading may be used with a single rail line or with multiple adjacent rail lines, or in a rail yard.
Figs. 37A - 37D show a system 370 according to the present invention for facilitating unloading of material from a container, e.g., but not limited to, sand from a railcar. The system 370 has a container 372 with receivers 371a in fluid communication with openings 371. A fluidizing unit 373 is disposed in or beneath each opening 371. Optionally, not shown, the units 373 may be wholly or partially within the receivers 371a.
In certain aspects, the system 370 has interconnected structural and support beams 378a-378e and/or known ISO container corners 378k. Multiple cross beams (not shown) may be used along the length of the container. Optionally, a system, e.g. as shown in Fig. 36 or in Fig. 37A, conforms to selected ISO dimensions and standards. Optionally, a system is made, designed, configured, sized, and of appropriate materials (e.g., metal, plastics, wood, composites, fiberglass, etc.) to handle and support the material from a fully-loaded railcar, e.g., in one aspect, about 286,000 pounds.
Water under pressure is supplied to the units 373 through connections 375 by a system 374, forming a slurry of material and water that flows into the container 372. This slurry is removed from the container 372 through connections 376 by a suitable removal system 377. In one aspect, the slurry is provided to a manifold 378 for further transfer through a single line coming from the manifold or through multiple lines from the manifold, individually, sequentially, or all simultaneously, for further transmission, transfer, or transport (e.g. but not limited to, to a short, medium length, or long pipeline or transmission line) or to any container, pipe, conduit, vessel, tank, or storage structure of any system herein.
The fluidising units for use in the systems herein may be those in these U.S. Patents and Applications, all incorporated fully herein for all purposes (with appropriate connections, conduits, controls, materials, flow lines, etc. properly sized): 9,527,013; 8,628,276; 8,371,323; 7,082,955; 7,066,207; 6,749,374; 6,659,118; 5,853,266; 5,195,582; 3,973,802; and U.S. Patent Applications Ser. Nos. 10/525,773 published Nov. 24, 2005 and 11/997,533 published on Sept. 11, 2008.
Certain systems of the present invention for unloading material, as described above, e.g. Figs. 36A, 36B and 37A: reduce dust generated in material unloading; reduce the need for or eliminate the need for traditional trains or traditional numbers of railcars; reduce the need for or eliminate traditional trans-loading facilities; reduce or eliminate the need for specialized railcars for unloading or specialized equipment; reduce the size of required rail lines or rail yards; can be installed in or associated with rail line sidings; and may be used in dust-sensitive or dust-free environments.

Claims

What is claimed is:
1. A system comprising
a hub for providing fracking materials for earth fracturing BO multiple wells in the earth, each well of the multiple wells laving a wellbore extending from the earth surface into the Barth,
the hub including structure on the earth surface,
pump apparatus associated with the hub,
lines between the hub and the wells through which fracking naterials from the hub are pumpable by the pump apparatus to the wells, and
a control system for controlling the pump apparatus.
2. The system of claim 1 further comprising
the hub including first container structure for holdingiater for use in earth fracturing, and
second container structure for containing solids useful in Barth fracturing.
3. The system of claim 1 further comprising
a fracking manifold between the hub and the lines for facilitating the pumping of fracking materials to each well, and the control system for controlling the fracking manifold and the flow of fracking materials from the hub to each well.
4. The system of claim 1 further comprising a back-up hub system for providing fracking materials to the wells simultaneously with the hub of claim 1, or alone without fracking materials being provided by the hub of claim 1,
the control system for controlling the back-up hub system.
5. The system of claim 1 further comprising
the hub including a solids system,
the solids system comprising multiple modules each for containing solids for use in the earth fracturing, the modules in intercommunication so that solids from all modules are evacuatable from the system and solids are introducible into the system,
a bottom opening beneath the modules, the bottom opening sufficiently large for accommodating the movement thereinto and out therefrom of a container for solids.
6. The system of claim 5 further comprising
the container comprising one of a vessel, tank, train, railcar, ship, pipeline, flowline, storage module, trailer, and truck.
7. The system of claim 1 further comprising
the hub including solids container structure for containing solids useful in earth fracturing, the container having an opening, and movement enhancing apparatus associated with the solids container either adjacent thereto, therein, or therein within the solids to enhance the movement of the solids through the opening and out from the container.
8. The system of claim 7 further comprising
the movement enhancing apparatus comprising a desander system.
9. The system of claim 7 further comprising
water supply apparatus,
the movement enhancing apparatus is a fluidizing unit, the water supply apparatus for supplying water to the fluidizing unit,
the fluidizing unit for forming a slurry of water and the solids to facilitate flow of the solids from the solids container structure.
10. The system of claim 9 further comprising
the fluidizing unit being one of A-T:
A. is a unit in which slurry formation is enhanced by vortex action within the unit;
B. the fluidizing unit is, comprising a discharge pipe
(2) and a supply duct (3) , the discharge pipe comprises a discharge inlet (4) and a discharge outlet (5), and the supply duct is formed by a housing (6) arranged around the discharge pipe defining an annular space (7) between an outer surface of said pipe and an inner surface of the housing, the supply duct comprises a pressurized liquid inlet (8) and a pressurized liquid outlet (9), wherein the pressurized liquid outlet, during use, is able to provide a pressurized liquid flow and said unit optionally including the solids container structure;
C. a vessel and the fluidizing unit for use adjacent or in the vessel, the unit including a discharge pipe which comprises a discharge inlet and a discharge outlet; and a supply duct which is formed by a housing arranged around the discharge pipe to thereby define an annular space between an outer surface of said discharge pipe and an inner surface of the housing, the supply duct comprising a pressurized liquid inlet and a pressurized liquid outlet; wherein the pressurized liquid outlet comprises one end of the annular space, said end having a circular or an elliptic cross-section in a plane substantially perpendicular to a centerline of the discharge pipe, such that the pressurized liquid outlet provides a pressurized liquid flow having a circular or an elliptic cross-section, optionally the pressurized fluid outlet proximate a bottom of the vessel and a major axis of the circular or elliptic cross-section of the pressurized liquid flow aligned with a longitudinal axis of said bottom;
D. the fluidizing unit further comprising swirl generating structure; E. the fluidizing unit comprising fluidizing apparatus comprising a flow chamber having a fluid inlet and a fluid outlet ; means for establishing a swirling flow in a fluid passing out of the fluid outlet; and a transport outlet for transporting fluidized solidsl away from the flow chamber, the transport outlet being situated externally of the flow chamber;
F. the fluidizing unit comprising a fluidizing apparatus comprising a flow chamber having a fluid inlet and a fluid outlet in which the flow chamber is closed off at its outlet end by an end wall, the flow chamber further comprising a housing and a flow guide, the flow guide being situated at least partially within the housing, where the flow guide is substantially tubular and has a side wall in which is formed at least one opening for establishing a swirling flow in a fluid passing out of the fluid outlet, in which the housing comprises a cap which fits over the flow guide, where the end wall is perpendicular to the flow guide; and a transport outlet for transporting fluidised solids away from the flow chamber, the transport outlet being situated externally of the flow chamber;
G. the fluidizing unit comprising a hopper, a pressure vessel and a valve element which controls a port between the hopper and the vessel, the valve element is retained closed against the port under pressure within the vessel, a fluidizing nozzle receiving transport fluid, such as water from a fluid line, the water supplied through the fluid line for fluidizing solids in the vessel and raising the pressure to maintain the valve element in the closed position, the fluidized solids material then suppliable to a transport pipeline from the vessel, solids loaded into the hopper depressing the valve element when pressure within the vessel is relieved, so allowing a fresh charge of the solids to enter the vessel for a subsequent cycle;
H. the fludizing unit comprising apparatus for transporting the solids, the apparatus comprising a vessel, a hopper for the solids, the hopper being situated above the vessel, a port providing communication between the hopper and the vessel, a valve element adapted to close the port, a liquid feed inlet for admitting liquid under pressure into the vessel, and an outlet for discharging a fluidized mixture of the liquid and the solids, wherein, optionally, the valve element is provided with a floatation device which biases the valve element upwards in the liquid, the floatation device being provided in the hopper and being connected to the valve element by a connecting element which extends through the port;
I. the fluidizing unit comprising a system for facilitating conveyance of flowable material through a conduit that creates a strong laminar flow of the material surrounded by a boundary layer flow of the same or a different flowable material, such that long transport distances through dramatic elevation and directional changes can be achieved, such a system comprising a blower assembly, an inlet conduit, an outlet conduit and a mixing chamber, wherein the mixing chamber includes an outer barrel, an inner barrel and an accelerating chamber, low pressure air supplied to the system by the blower assembly and mixed with particulate material - solids, the air/solidsl mixture is transportable through the mixing chamber into the accelerating chamber and through the outlet conduit, optionally the solids mixed with the air in the accelerating chamber. And optionally the system including only the mixing chamber, where a flow of at least one flbwable material in the form of high or low pressure gas, liquid, and/orsolids suspended within the gas or liquid enters either laterally or axially, forms boundary layer and laminar flows, and exits through the accelerating chamber;
J. the fluidizing unit comprises a flow development chamber for creating a vortex flow and a laminar flow;
K. the fluidizing unit comprises a pneumatic conveying system for conveying solids through a conduit that creates a strong laminar flow of solids and air surrounded by a boundary layer flow of air, such that long transport distances through dramatic elevation and directional changes can be achieved, such a system comprising a blower assembly, an inlet conduit, an outlet conduit and a mixing chamber, wherein the mixing chamber includes an outer barrel, an inner barrel and an accelerating chamber, low pressure air supplied to the system by the blower assembly and mixed with solids, the air/material mixture transported through the mixing chamber into the accelerating chamber and through the outlet conduit, and optionally the solids mixed with the air in the accelerating chamber;
L. the fluidizing unit comprising a supply duct which is arranged to be fed with liquid under pressure, and a discharge duct within the supply duct and projecting beyond the outlet of the supply duct, the end of the supply duct closable when the fluidizing unit is not in use, a screen associated with the supply duct, the screen having at least one oblique opening, and being positioned so that liquid passing through the supply duct passes through the or each opening in the screen and is caused to swirl.
M. the fluidizing unit comprising a supply duct which is arranged to be fed with liquid under pressure, and a discharge duct or ducts within the supply duct, the end of the supply duct of the fluidizing unit being closable when the fluidizing unit is not in use;
N. the fluidizing unit comprising a supply duct which is arranged to be fed with liquid under pressure, and a discharge duct within the supply duct and projecting beyond the outlet of the supply duct, wherein a screen or screens is provided at the outlet of the supply duct of the fluidizing unit, the screen having at least one oblique opening positioned so that liquid passing through the supply duct passes through the opening (s) in the screen and is caused to swirl about the axis of the supply duct, the discharge duct being provided with a radially outwardly projecting annular flange, and the screen (s) provided between the end of the supply duct and the annular flange;
O. the fluidizing unit comprising apparatus is disclosed for use adjacent or for insertion into a conveying system line wherein solids are conveyable by a liquid or a gaseous medium, the apparatus accepting liquid or a pressurized gas input and developing therefrom in an internal chamber and annular orifice a flow having an internally-directed refluidizing component and a longitudinally-directed conveyor film component; P. the fluidizing unit comprising an inlet pipe having a first end constructed for connection into the conveying system in axial flow alignment with a liquid or gaseous stream, an outlet pipe having a first end constructed for connection into the conveying system in axial alignment downstream of said inlet pipe, said outlet pipe having an axially-symmetric expanding contour fitted over said inlet pipe, and having an end plate closing about said inlet pipe, said end plate being inclined at a desired angle from a plane which is perpendicular to the . inlet pipe axial direction, a chamber external said inlet pipe and formed by the interior surfaces of said outlet pipe expanding contour and end plate, and the exterior surface of said inlet pipe, and having an annular output orifice about the interior end of said inlet pipe, an inlet for receiving liquid or pressurized gas, opening into said chamber at a point approximately tangential to the chamber inner surface and adjacent the inclined end plate at a position closest to said inlet pipe first end, and structure for telescoping said inlet pipe into said outlet pipe expanded contour through said inclined end plate, for varying the chamber output annular orifice size;
Q. the fluidizing unit comprising fluidizing apparatus that includes a supply duct for supplying liquid under pressure to a lower portion of a vessel containing fluidizable soldis, the supply duct extending into the vessel, the outlet end of the apparatus including one or more jets for directing the flow of liquid into the vessel, and an outlet duct for removing fluidized solids from the vessel; R. the fluidizing unit comprising a fluidizing apparatus comprising a supply duct for supplying liquid under pressure to a lower portion of a vessel containing fluidizable solids, the supply duct extending into the vessel and including at the outlet end thereof one or more jets for directing the flow of liquid into the vessel at a desired angle, optionally substantially transversely to the major axis of the supply duct, and an outlet duct for removing the fluidized solids from the vessel, wherein the inlet end of the outlet duct is protected from ingress of non-fluidized material by a flange member located between the jets and the inlet end of outlet duct, the flange member adapted to divert the flow of fluidized material past the underside of the flange member before entering the inlet end of the outlet duct;
S. the fluidizing unit comprising a fluidizing apparatus comprising a vessel having an inlet, a plurality of outlets and a nozzle, through which a pressurized fluid can be fed into the vessel, the outlets spaced apart at different heights from a base of the vessel and controlled by valves enabling fluidized solids to be removed in layers from the vessel, and optionally a single outlet raised or lowered to a desired position in the vessel; or
T. the fluidizing unit comprising a vessel having: a base, an inlet, a plurality of outlets positioned at different heights from one another from the base, a plurality of respective removable inserts provided in the outlets, a fluidizing nozzle disposed in the vessel above the base of the vessel in a manner to create a swirling flow within the vessel, and a common outlet line to which the outlets are selectively connectable.
11. The system of claim 1 further comprising
a source of solids for the hub, the solids comprising sand, the source of solids comprising a frac sand mine, and
a rail system to facilitate transfer of sand from the frac sand mine to the hub.
12. The system of claim 1 further comprising
the lines including pipelines between the hub and at least some of the wells for providing fracking materials to at least some of the wells,
the fracking materials comprising fracking fluid with water and solids therein, the solids including proppants, fracking fluid additives, or both.
13. The system of claim 1 further comprising
collection apparatus for collecting a fluid produced from one of the wells, the fluid comprising collected fluid,
processing apparatus for processing the collected fluid, producing at least one resulting fluid from the collected fluid, transfer apparatus for transferring the resulting fluid from the processing apparatus to another location.
14. The system of claim 1 wherein the fracking materials include water, sand, proppants, fracturing fluid additives, and any combination of any two or more of these.
15. A container as the second container structure of claim 2, the container further comprising
movement enhancement apparatus associated with the container for facilitating the movement of solids from the· container .
16. The container of claim 15 wherein the movement enhancement apparatus is a fluidizing unit.
17. The container of claim 16 wherein the fluidizing unit produces a slurry with solids and water therein using vortex action and wherein the container comprises one of vessel, tank, train, railcar, ship, pipeline, flowline, storage module, trailer, and truck.
18. A method for producing a slurry of water and solids, the solids comprising proppants for use in fracturing earth, the method comprising
introducing the solids and water into a movement enhancing apparatus, the movement enhancing apparatus comprising a fluidizing unit,
with swirling action in the fluidizing unit, producing a slurry of the water and the solids.
19. A method for fracturing earth, the earth beneath an earth surface, the method comprising
providing fracturing material from a system to multiple wells, each of the multiple wells including a wellbore into the earth from a surface of the earth down into the earth, the system comprising
a hub for providing fracking materials for earth fracturing to multiple wells in the earth, each well of the multiple wells having a wellbore extending from the earth surface into the earth,
the hub including structure on the earth surface,
pump apparatus associated with the hub,
lines between the hub and the wells through which fracking materials from the hub are pumpable by the pump apparatus to the wells, and
a control system for controlling the pump apparatus, the method further comprising using the pump apparatus, pumping the fracking materials through the lines to the wells, and controlling the pumping with the control system.
20. The method of claim 19 further comprising the hub including first container structure for holding water for use in earth fracturing, and
second container structure for containing solids useful in earth fracturing, the second container structure comprising multiple modules each for containing solids for use in the earth fracturing, the modules in intercommunication so that solids from all modules are evacuatable from the system and solids are introducible into the system,
a bottom opening beneath the modules, the bottom opening sufficiently large for accommodating the movement thereinto and out therefrom of a container for solids, the container comprising one of a vessel, tank, ·. train, railcar, ship, pipeline, flowline, storage module, trailer, and truck, the solids including sand, proppants, fracturing fluid additives, or a combination of any two or more of these, and movement enhancing apparatus associated with the modules either adjacent thereto, therein, or therein within the solids to enhance the movement of the solids through the opening and out from the modules, optionally the movement enhancement apparatus comprising a fluidizing unit:.
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