Note: Descriptions are shown in the official language in which they were submitted.
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MOBILE MATERIAL HANDLING AND METERING SYSTEM
FIELD OF THE INVENTION
[0001] The present invention pertains in general to material handling systems
and in
particular to a mobile material handling and metering system for storing and
delivering
granular material, and an associated method.
BACKGROUND
[0002] Granular material, such as sand, is used in bulk quantity in a number
of
applications. For example, in hydraulic fracture drilling by oil and gas and
other industries,
fracturing fluid, along with a granular proppant material such as sand and/or
ceramics, is
pumped into a drill well to create and prop open fractures in rock. Often,
activities requiring
large amounts of granular material are performed in a remote location,
requiring granular
material to be shipped in for example by road, rail or water.
[0003] For such activities, it is desirable to have sufficient and often large
amounts of
granular material readily available for adequately reliably carrying out
operations. For
hydraulic fracture drilling, storage facilities may be required, for example,
to hold 50,000
cubic feet of proppant, and hence must be adequately large, as well as capable
of supporting
the resulting weight of proppant. However, in many cases, granular materials
are only
required over a limited time period, for example during the drilling
operations. Thus, large,
permanent on-site storage facilities for the required granular materials are
often not
economical.
[0004] Typically, proppant is stored at a well site in fixed vertical silos
and supplied by a
dry-bulk tanker and blown into the silo. This method of storage requires that
the silos are
transported on flat-deck trailers and hoisted into position using large
cranes. The set-up time
for this type of operation may be extensive, for example lasting on the order
of days.
Additionally, the silo filling operation may require a dry-bulk blower, which
is costly, noisy
and creates an undesirably large amount of dust. Furthermore, limited site
space may place
restrictions on overall size of this type of system, and vehicle compliance
regulations may
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limit overall dimensions of components, such as silos, of system which are to
be transported
by vehicles such as flat-deck trailers.
[00051 United States Patent Application Publication No. 2008/0008562 discloses
a
method of transporting and storing an oilfield proppant, wherein proppant is
transported to
and accumulated at a storage facility. However, the storage facility is in the
form of a large
building which is not well-suited for portability.
[0006] United States Patent No. 6,293,689 discloses a multi-trailer mobile
concrete
hatching and mixing plant, including a concrete silo trailer and an aggregate
trailer.
However, this plant comprises a specific, closed arrangement of trailers and
is limited in the
amount of material that can be stored and in the rate at which material can be
added or
removed from the plant.
[0007] United States Patent Application Publication No. 2008/0179054 discloses
a
method and system for expandable storage and metering of proppant or other
materials. A
portable storage and metering device is transported to a well site and there
expanded and
filled with proppant, which is metered out as required. However, this approach
is limited in
scale of proppant material that can be stored and metered.
[0008] Therefore there is a need for a method and system for mobile storage
and delivery
of granular material that is not subject to one or more limitations of the
prior art.
[0009] This background information is provided for the purpose of making known
information believed by the applicant to be of possible relevance to the
present invention.
No admission is necessarily intended, nor should be construed, that any of the
preceding
information constitutes prior art against the present invention.
SUMMARY OF THE INVENTION
[0010] An object of the present invention is to provide a method and system
handling
granular material. In accordance with an aspect of the present invention,
there is provided a
system for handling granular material, the system comprising: a delivery
module configured,
in a delivery module operational configuration, to receive said granular
material and to
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convey said granular material to a predetermined delivery location; and one or
more mobile
storage modules adjacent to the delivery module, each of the one or more
mobile storage
modules configured, in a mobile storage module operational configuration, to
hold and
dispense said granular material downward to the delivery module.
[0011] In accordance with another aspect of the present invention, there is
provided a
delivery module for handling granular material, the delivery module
configured, in a delivery
module operational configuration, to receive said granular material from one
or more mobile
storage modules and to convey said granular material to a predetermined
delivery location,
the one or more mobile storage modules adjacent to the delivery module, each
of the one or
more mobile storage modules configured, in a mobile storage module operational
configuration, to hold and dispense said granular material downward to the
delivery module.
[0012] In accordance with another aspect of the present invention, there is
provided a
mobile storage module for handling granular material, the mobile storage
module configured,
in a mobile storage module operational configuration, to hold and dispense
said granular
material downward to an adjacent delivery module, the delivery module
configured, in a
delivery module operational configuration, to receive said granular material
from the mobile
storage module and to convey said granular material to a predetermined
delivery location.
[0013] In accordance with another aspect of the present invention, there is
provided a
method for handling granular material, the method comprising: providing a
delivery module
configured to receive said granular material and to convey said granular
material to a
predetermined delivery location; and providing one or more mobile storage
modules adjacent
to the delivery module, each of the one or more mobile storage modules
configured to hold
and dispense said granular material downward to the delivery module.
BRIEF DESCRIPTION OF THE FIGURES
[0014] These and other features of the invention will become more apparent in
the
following detailed description in which reference is made to the appended
drawings.
[0015] Figure 1 illustrates a system for handling granular material, in
accordance with
embodiments of the invention.
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[0016] Figure 2 illustrates a mobile storage module in a transportation
configuration, in
accordance with embodiments of the invention.
[0017] Figure 3 illustrates a perspective view of a mobile storage module in
an operational
configuration, in accordance with embodiments of the invention.
[0018] Figure 4 illustrates an elevation view of a mobile storage module in an
operational
configuration, in accordance with embodiments of the invention.
[0019] Figure 5 illustrates a frame of a mobile storage module, in accordance
with
embodiments of the invention.
[0020] Figure 6 illustrates a flexible chute for fitting to an output port of
a mobile storage
module, in accordance with embodiments of the invention.
[0021] Figure 7 illustrates a variable aperture device for operatively
coupling to an output
port of a mobile storage module, in accordance with embodiments of the
invention.
[00221 Figure 8 illustrates a frame of a mobile storage module, in accordance
with
embodiments of the invention.
[0023] Figure 9 illustrates a top view of a delivery module, in accordance
with
embodiments of the invention.
[0024] Figure 10 illustrates an end view of a delivery module, in accordance
with
embodiments of the invention.
[0025] Figure 11 illustrates a discharge end of a delivery module in both
transportation
and operational configurations, in accordance with embodiments of the
invention.
[0026] Figure 12 illustrates a partial top view of a system for handling
granular material,
in accordance with embodiments of the invention.
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DETAILED DESCRIPTION OF THE INVENTION
Definitions
[00271 The term "granular material" is used to define a flow-able material
comprising
solid macroscopic particles, such as sand, gravel, or the like.
[00281 The term "proppant" is used to define a granular material used in
drilling, for
example by oil and gas industries. Proppant comprises appropriately sized and
shaped
particles which may be mixed with fracturing fluid to "prop" fractures open
after a hydraulic
fracturing treatment. Proppant may comprise naturally occurring sand grains of
a
predetermined size, or engineered materials, such as resin-coated sand,
ceramic materials,
sintered bauxite, or the like.
[00291 As used herein, the term "about" refers to a +/- 10% variation from the
nominal
value. It is to be understood that such a variation is always included in a
given value provided
herein, whether or not it is specifically referred to.
[00301 Unless defined otherwise, all technical and scientific terms used
herein have the
same meaning as commonly understood by one of ordinary skill in the art to
which this
invention belongs.
[00311 An aspect of the present invention provides for a system for handling
granular
material, for example for storage and delivery of proppant for use in
hydraulic fracturing at a
drill well site. The system comprises a delivery module configured to receive
said granular
material at a reception area thereof and to convey said granular material to a
predetermined
delivery location. The delivery module may comprise one or more mobile powered
conveyor
systems, for example at least partially for substantially horizontal
conveyance of the granular
material. The system further comprises one or more mobile storage modules,
each
configured to hold said granular material and to dispense said granular
material downward to
the delivery module. In an operational configuration, the mobile storage
modules are
arranged adjacent to the delivery module. In a transportation configuration,
the mobile
storage modules may be configured and towed as semi-trailers and may comprise
a container
pivotably connected to a base, which may be raised into position for gravity-
assisted
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dispensing of granular material. The delivery module may also further be
configured in a
transportation configuration for towing as a semi-trailer.
[00321 Another aspect of the present invention provides for a delivery module
for
handling granular material, the delivery module as described above. Another
aspect of the
present invention provides for a mobile storage module for handling granular
material, the
mobile storage module as described above.
[00331 Figure 1 illustrates a system 100 for handling granular material in
accordance with
embodiments of the present invention. The system 100 is illustrated as
arranged in an
operational site configuration, with a plurality of mobile storage modules
110, 115 arranged
around a delivery module 120. As shown, there are five mobile storage modules
110 in a
first bank on one side of the delivery module 120, and five mobile storage
modules 115 in a
second bank on another side of the delivery module 120 opposite the first
bank. However,
this number may be reduced or increased. If the number is increased, the
delivery module
portion 120 may be expanded in length, for example by adding one or more
additional
conveyors arranged end-to-end. Other arrangments, such as providing plural
delivery
modules in parallel, may also be used. The mobile storage modules 110, 115 are
arranged so
that they may individually discharge granular or flow-able material such as
proppant onto
one or more, centrally located main conveyors of the delivery module 120. The
granular
material is conveyed by the main conveyors to one or more discharge conveyors
130, which
convey the material to a height appropriate to allow the material to feed one
or more blender
modules 140. Each blender module 140 may be a mobile unit used to blend
fracking
chemicals, proppant and bulk fluid. Alternatively, the discharge conveyors 130
may be
configured for delivering granular material to another appropriate location or
equipment, for
example to re-load a bulk tanker during well-site decommissioning.
[00341 In some embodiments, there may be a substantially independently
variable number
of mobile storage modules provided on each side of the mobile storage module.
For
example, between zero and ten mobile storage modules may be arranged in a
first bank along
one side of a delivery module, and between zero and ten mobile storage modules
may be
arranged in a second bank along another side of a delivery module opposite the
first bank.
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The number of mobile storage modules in the first and second bank need not be
even. For
example, two, three or four mobile storage modules may be arranged in the
first bank, and
five or six mobile storage modules may be arranged in the second bank.
[0035] An aspect of the present invention provides for a method for handling
granular
material. The method comprises providing a delivery module configured to
receive said
granular material and to convey said granular material to a predetermined
delivery location.
The delivery module may be transported to a desired site in a transportation
configuration
and then converted to an operational configuration for receiving and conveying
the granular
material. The method further comprises providing one or more mobile storage
modules
adjacent to the delivery module, each of the one or more mobile storage
modules configured
to hold and dispense said granular material downward to the delivery module.
The mobile
storage modules may be transported to a desired site in a transportation
configuration and
then converted to an operational configuration for holding and dispensing the
granular
material.
[0036] Embodiments of the present invention provide for robustness to
component failure
or mechanical breakdown by providing redundancies for one or more components.
For
example, the delivery module may comprise plural conveyor systems, and the
system may be
configured to facilitate continued operation in the event that one or more
conveyor systems
break down. As another example, each of the mobile storage modules may include
interchangeable components, such as hydraulic power packs, which may be
connected for
use in another mobile storage module should that component of the other mobile
storage
module fail or break down. Plural components may be also used in series or
parallel to
augment specific operations.
[0037] Embodiments of the present invention may provide for one or more
mechanical
features facilitating operation of mobile storage modules and/or delivery
modules. For
example, one or more modules may comprise a rock-over chassis, which may
operate as a
semi-trailer chassis in the transportation configuration, and as a support
structure engaging
ground over an adequately large surface area in the operational configuration.
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[00381 In embodiments of the present invention, each of the mobile storage
modules and
delivery modules are reconfigurable between transportation and operational
configurations.
In the transportation configuration, each module may be separately
transportable in an
adequately compact configuration. In the operational configuration, plural
modules may be
configured and arranged together for accepting, storing, conveying and
delivering granular
material.
100391 Embodiments of the present invention are modular and expandable, which
enables
a configurable storage capacity for granular material such as proppant, and/or
a configurable
capacity for adding and/or removing granular material. The number of mobile
storage
modules may be adjusted as required, to provide the appropriate capacity. In
some
embodiments, additional delivery modules or delivery module expansion units
may also be
provided as desired. Excess storage modules may remain unused or may be used
at another
site to improve operational efficiencies. Each mobile storage module provides
its own
storage capacity, and plural mobile storage modules may be loaded with
granular material at
the same time, thereby facilitating quicker loading or reloading. In some
embodiments,
plural storage modules may further feed the delivery module at the same time,
thereby
providing granular material to the delivery module at a higher rate than from
a single storage
module.
[00401 At least some embodiments of the present invention may provide
improvements in
terms of operational efficiency, set-up time, transportation requirements,
storage and asset
tracking requirements, and the like, for example by requiring a relatively
small number of
component modules when compared with some prior art solutions.
Mobile Storage Module
[00411 The present invention comprises one or more mobile storage modules for
holding
and dispensing granular material. The number of storage modules utilized may
be adjusted
as needed for a given operation, from one to a predetermined maximum number
which may
depend at least in part on delivery module capacity. Each of the mobile
storage modules may
be reconfigurable between a transportation configuration and an operational or
site
configuration. In the transportation configuration, each mobile storage module
may be
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configured as a separately transportable trailer or semi-trailer. In the
operational
configuration, each mobile storage module may be configured as a granular
material storage
container or silo.
100421 In embodiments of the present invention, each mobile storage module
comprises a
frame and a container portion, such as an enclosed box, supported by the frame
and pivotably
coupled thereto. The mobile storage module frame may be referred to and/or
associated with
a chassis. The container portion is configured, for storing granular material
and comprises an
input port for receiving the granular material and an output port for
dispensing the granular
material. The container portion may be substantially enclosed on all sides,
except for the
input port and output port, which may comprise controllably-sized apertures.
The mobile
storage module may further comprise an actuating system configured to pivot
the container
between a lowered position and a raised position. In the raised position, the
input port is
located above the output port to allow the granular material to flow from
input to output with
assistance of gravity. The mobile storage module may further comprise a
loading system,
such as an in-feed elevator, conveyor, bucket conveyor, or the like,
operatively coupled to the
input port to facilitate loading of granular material into the container
portion.
[00431 In some embodiments, the mobile storage module may comprise a discharge
chute,
gate valve, and/or variable discharge aperture valve, operatively coupled to
the output port to
facilitate controlled and metered flow of granular material from the container
portion. The
collective flow from container plural mobile storage modules may also be
controlled and
metered by controlling and metering flows from plural mobile storage modules.
The variable
discharge chute, metering iris or aperture may facilitate remote, or manual,
and ultimately
combined, control of the rate of discharge from one or more storage units. A
variable
aperture at an output port may allows for a substantially continuous control
of granular
material flow from zero flow to a predetermined maximal flow.
[00441 In some embodiments, the mobile storage module may further comprise a
hydraulic power pack for powering components such as the actuating system,
loading
system, and output port valves. In some embodiments, the mobile storage module
may be
configured into a transportation configuration corresponding to a trailer or
semi-trailer
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complying with predetermined laws, regulations and/or and height and weight
requirements,
for transportation by a road tractor or other appropriate on-road, off-road,
rail or water
vehicle.
[0045] Figure 2 illustrates a mobile storage module 200 arranged in a
transportation
configuration, as a semi-trailer mounted on a road tractor 210, in accordance
with
embodiments of the present invention. The semi-trailer may be configured to
comply with
applicable laws and regulations regarding size, length, weight, and the like.
[0046] In some embodiments, for example as illustrated in Figure 2, the
container portion
225 of a mobile storage module 200 is formed as a rigid box of a generally
rectangular
structure, tapered from front to rear so that the container top is at maximum
allowable vehicle
height when in the transportation configuration, in accordance with
predetermined laws
and/or transportation regulations. Other features illustrated in Figure 2 are
also described
herein.
[0047] Figures 3 and 4 illustrate, in perspective and elevation views,
respectively, a
mobile storage module 200 arranged in a site configuration as an erected silo,
in accordance
with embodiments of the present invention. The mobile storage module 200 is
detached from
a road tractor and set up at an appropriate location, for example adjacent to
a delivery module
and possibly one or more other mobile storage modules. A loading system such
as an
elevator 310 or other conveyor is connected to an input port 320. Granular
material may be
loaded onto the elevator 310 from an appropriate container vehicle. The
elevator 310
transports the material to the input port 320, where it may be stored in the
container portion
225, and/or flowed therethrough to an output port. The mobile storage module
200
comprises, at its base, a frame 235, which may be substantially rigid and may
span
approximately the unit's full length and width. The container portion 225 is
raised into
position by a actuating system, for example in the form of a hydraulic
actuator 350, for
example comprising a set of one or more hydraulic piston-cylinder assemblies,
which are
coupled to the container portion 225 and the frame 235 and controllably
powered by a
hydraulic power pack or other source of pressurized hydraulic fluid. The
hydraulic actuators
may be attached, via pin joints or other pivotable joints, at one end to the
container portion
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225 and at the other end to the frame 235, such that expansion of the
hydraulic actuators 350
effects differential movement between the container portion 225 and frame 235
in an arc,
thereby raising and pivoting the container portion 225 from the trailer
chassis to a desired or
predetermined angle. Embodiments of the present invention may be configured
for pivoting
the container portion to one or more predetermined or selectable angles,
adequate for
facilitating flow of material from the input port to the output port under
gravity. Such an
angle may depend on factors such as the material involved, material grain
size. flow-ability,
height availability, weight distribution requirements, and the like. In some
embodiments, the
container portion may be pivoted at an angle of about 40 degrees relative to
the frame. In
some embodiments, an agitator may be provided for agitating the container
portion, thereby
controllably increasing flow-ability of granular material at one or more
predetermined angles.
[00481 As also illustrated in Figures 3 and 4, the container portion 225 may
comprise a
fully enclosed rigid box approximately dimensionally equal to the frame 235 in
length and
width. The container portion 225 may be attached to the frame 235 by way of a
hinge 230,
for example located rearward of the wheel axles 370. In another embodiment,
the wheel
axles 370 may be coupled to both the container portion 225 and the frame 235
and may act as
a hinge therebetween.
[0049] In some embodiments, one or more hydraulic piston-cylinder assemblies
or other
substantially linear hydraulic actuators 350 are configured such that, in
their collapsed state
corresponding to the transportation configuration, one end is substantially
higher than the
other end. Thus, at commencement of expansion, the actuators can generate a
sufficient
vertical axis component of thrust to initiate movement of the container
portion 225. For a
given size of hydraulic actuator, this may be effected by positioning the
upper end of the
hydraulic actuator, for example a piston rod end thereof, substantially above
the frame 340
and possibly into a region located within the convex hull of the container
portion 225. In
this arrangement, volume which could otherwise potentially be occupied by
usable granular
payload within the container portion 225 may, in some embodiments, be
sacrificed to make
room for a portion of the hydraulic actuator or actuators 350.
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[0050] In some embodiments, the main hydraulic actuators 350 are configured so
as to be
substantially parallel and within the frame 235 when in the transportation
configuration, with
a first end of the main hydraulic actuators 350 connected to the frame 235 and
a second end
coupled to a bottom surface of the container portion 225, for example by way
of a yoke or
lug extending below the container portion 225. In this arrangement, the
hydraulic actuators
350 may then substantially lie outside of the convex hull of the container
portion 225,
thereby increasing potential granular material storage capacity thereof. A
second set of one
or more initiating hydraulic actuators, for example piston-cylinder assemblies
oriented
substantially vertically, may be provided, permanently or as needed, for
initially raising the
container portion 225 to an orientation at which the main hydraulic actuators
350 are able to
provide sufficient vertical thrust to raise the box to its full height. At
this point, the main
hydraulic actuators 350 may take over the container portion load.
[0051] For example, as illustrated in Figure 2, the initiating hydraulic
actuators 220 may
be located at an end of the container portion 225 opposite the hinge 230, the
hydraulic
actuators 220 supported by the frame 235. In some embodiments, the initiating
hydraulic
actuators 220 may be pin-jointed to the frame 235 at a lower end and bear, for
example non-
rigidly, against a box-mounted cup structure 240 at an upper end. At the point
at which the
main hydraulic actuators 350 take over lifting duty, the initiating hydraulic
actuators 220 may
reach maximum stroke and loose contact, at their upper ends, with the box-
mounted cup
structure 240.
[0052] In some embodiments, deployable rigid bracing 380, as illustrated in
Figures 3 and
4, may be provided. The bracing 380 may be, for example, hinged at one end and
free
sliding at the other end. The bracing 380 may facilitate supporting the
container portion 225
of a mobile storage unit 200 in a raised, operational configuration, thereby
reducing or
eliminating the need to maintain hydraulic power after the container portion
is raised and the
rigid bracing 380 locked into place.
[0053] In some embodiments, a rigid brace 380 may be provided for bracing the
container
portion 225 when in the raised position. As illustrated in Figures 3 and 4, a
first end of the
brace 380 may be pin jointed to the underside of the container portion 225 at
a predetermined
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location 382, and a second end 384 of the brace 380 may be free to slide on
and/or over the
trailer chassis while raising the container portion 225. The second end 384
may be deployed
and locked into place at a location 386 of the frame 235, for example by
forcing the brace to
arc over centre into a fixed pocket at the location 386 and then slightly
lowering the container
portion 225, and/or by pinning the second end 384 to the frame 235 at location
386.
[0054] In some embodiments, after raising the container portion 225, the
hydraulic
actuators 350 may be de-powered such that temperature induced hydraulic drift
does not
induce unexpected box loading. The rigid bracing structure 380 may therefore
remove
dependence upon the hydraulic actuators 350 after said raising. At full
elevation the
container portion 225 functions at a storage silo. As illustrated, the
container portion 225
need not be fully vertical, but may be configured at an angle such as about 40
degrees. The
system may provide for a set of mobile self-deploying silos forming a storage
accumulator of
variable capacity.
[0055] In embodiments of the present invention, the front end of the container
portion
includes an input port through which the container portion may be loaded with
granular
material, for example input port 320 as illustrated in Figure 3. In some
embodiments, the
front end of the container portion may further include an opening through
which the loading
system, for example elevator 310 illustrated in Figure 3 may be loaded for
storage and
transportation when in the transportation configuration. The stored elevator
310 is illustrated
in Figure 2.
[00561 As further illustrated in Figures 2 and 4, a discharge chute 250 may be
provided at
the rear of the container portion 225. The discharge chute 250 is configured
in-line and in
fluid communication with the output port and is oriented and located to
position discharged
granular material toward the delivery module for reception thereby. For
example, the
discharge chute 250 may be positioned to discharge the granular material onto
a discharge
conveyor of the delivery module. In some embodiments, the discharge chute 250
may be
positioned low and close to the discharge conveyor to reduce unused volume in
the
lowermost rear corner of the box.
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[0057] In some embodiments, as illustrated in Figure 5, the frame 235 may be
constructed
from standard structural members, such as steel beams, to form a ladder frame
chassis. At
one end of the chassis, a set of one or more axles may be fitted at location
510. At the other
end of the chassis, a kingpin and coupler structure, or other structure
suitable for coupling to
a standard or non-standard truck fifth wheel may be provided at location 520.
[0058] Figure 5 further illustrates the frame or trailer chassis 235
comprising a series of
longitudinal beams 530 and transverse cross-members 540 oriented to form a
rock-over
chassis, in accordance with embodiments of the present invention. The chassis
may
incorporate, toward the front end 520 a coupler structure with a standard SAE
kingpin and
toward the rear end 510 a suspension assembly and one or more axles and wheels
operatively
coupled thereto. In some embodiments, the suspension assembly may be located
and
oriented such that by deflating air springs thereof, the frame 235 can be
lowered into contact
with the ground to form a full length bearing structure.
[0059] In some embodiments, the rock-over chassis front end and/or rear end
may be
lowered to ground by an external crane. In some embodiments, the present
invention may
comprise hydraulic landing legs operatively coupled to the frame or rock-over
chassis. The
hydraulic landing legs may extended to contact ground to support the frame 235
while the
road tractor drives away, the legs then fully retracted for lowering of the
chassis to ground.
The frame or rock-over chassis may be configured to present adequate ground
contact area so
that the ground footprint pressure remains below a predetermined maximum
level.
[0060] In some embodiments, the in-feed elevator 310, for example as
illustrated in
Figures 3 and 4, may be dimensioned such that the elevator 310 reaches from
the input port
320 to substantially ground level, when the elevator 310 is fully deployed and
the container
portion 225 is elevated to its full height in an operational configuration.
Thus, the elevator
310 can transport material from approximately ground level to the height of
the input port
320. In some embodiments, the container portion 225 may be raised while empty,
and
subsequently loaded via the elevator 310 at full elevation, thereby decreasing
lifting capacity
requirements of the hydraulic actuators 350. In some embodiments, the elevator
310 may be
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tilted upward and inserted into the container portion 225 for stowage in the
transportation
configuration, for example as illustrated in Figure 2.
[00611 In some embodiments, the in-feed elevator 310 comprises a continuous
belt
equipped with cleats, buckets or other features for conveying material upward
to the input
port. The conveyor belt may be contained within a rigid frame extending
approximately the
full length of the conveyor belt such that the frame allows the conveyor
system to be non-
continuously supported along its length. The frame may be hingedly coupled at
the upper
end to a fixed location on the container portion 225, and may be supported by
deployable
legs or wheels at its lower end to ground. The frame is configured with a
predetermined
structural rigidity to resist bending due to payload and system weight, and
buckling due to
belt tension.
[0062] In some embodiments, the in-feed elevator 310 may be deployable from a
stored
position within the container portion 225, for example stowed and deployed via
the container
portion input port 320 or another port. Such a port may be located at the
upper front corner
of the front face of the container portion. The in-feed elevator 310 may, in
deployment, be
tilted, for example by a hinge, to an approximately vertical orientation such
that the
lowermost end of the belt is proximate to ground. In some embodiments, the
deployed in-
feed elevator 310 may be supplied with granular material by a standard low-
elevation belly
unloading conveyor directly from a series of bulk tankers or other bulk
material transporters.
In some embodiments, the in-feed elevator may be coupled, at an end proximate
to the input
port, to a set of one or more outboard rollers. The outboard rollers may be
located on both
sides of the frame. A pair of channels, configured to accommodate the rollers
therein, may
also be provided inside of the container portion for stowage of the in-feed
elevator in the
transportation configuration. In some embodiments, a fixed roller, for example
at location
312 as illustrated in Figure 4, may be located at the lowermost edge of the
port receiving the
in-feed elevator, the fixed roller bearing against the underside of the in-
feed elevator frame,
thereby providing support during storage and deployment.
[0063] Figure 6 illustrates a flexible chute 600 provided in accordance with
embodiments
of the invention. The flexible chute 600 may be fitted to a discharge chute or
output port of a
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mobile storage module for directing granular material to the delivery module.
The flexible
chute 900 comprises a set of interlocking conical members 610, such as
approximately
concentric diminishing cones, which are movable relative to each other so that
the chute 600
output may be configurably located as needed for granular material discharge.
[00641 The rear end of the container portion of a mobile storage module
comprises an
output port, for example formed in a flat structural wall. In some
embodiments, the output
port may comprise a hydraulically or manually operated variable aperture or
other metering
device. In some embodiments, a discharge chute may be coupled to the output
port.
[00651 Figure 7 illustrates a variable aperture device 700 operatively coupled
to the output
port, in accordance with some embodiments. The aperture 710 may be varied in
size by
pivoting of a plurality of plates 720, pivotably coupled to a main body of the
variable
aperture device 700. The variable aperture device 700 may comprise a series of
overlapping
plates 720, arranged such that they form a roughly circular aperture 710 of
variable radius.
[00661 In some embodiments, rapid isolation of proppant flow is effected by a
gate
comprising a reinforced flat plate sliding in channels perpendicular to the
proppant flow and
arranged such that full withdrawal of the plate allows substantially maximum
flow and full
insertion of the plate allows substantially no flow. This gate valve may be
manually operated
with a local mechanically-advantaged lever or remotely by way of a quick-
acting hydraulic
cylinder. Alternatively a butterfly valve may be used for this application.
[00671 Figure 8 illustrates a frame 810 of a mobile storage module, in
accordance with
embodiments of the present invention, which extends partway underneath the
container
portion 820 to an intermediate location 815. The coupler structure for
coupling to the road
tractor 830 may then be incorporated into the container portion 820 rather
than the frame
810. This arrangement reduces weight of the mobile storage module and
potentially
increases allowable payload weight and/or available payload volume. In this
configuration,
the ground bearing envelope is reduced compared with a full-length frame, and
thus
additional frame surface area may be required to maintain adequately low
bearing pressure.
In some embodiments, the partial-length frame 810 may be configured to allow
for frame
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adaptation to increase ground bearing area. For example, skids, deployable
footings,
sheeting, external supports, or the like, may be provided for this purpose.
[0068] In some embodiments, the mobile storage modules may be configured for
accepting granular material from delivery vehicles other than dedicated dry-
bulk proppant
transporters and blowers. For example, a mobile storage module and/or in-feed
elevator
thereof may be adaptable or configured for use with simple belly unloading
vehicles such as
grain trailers, or other locally available equipment. This may allow for
substantially local
infrastructure and equipment, such as associated with a local agricultural
industry, to service
and supply proppant, or other granular material, rather than specialized,
expensive equipment
sourced from a central location. This may be particularly advantageous in
remote locations
for operational reasons such as cost and scheduling.
Delivery Module
[0069] The present invention comprises one or more delivery modules,
configured to
receive granular material from the mobile storage modules and to convey the
granular
material to a predetermined delivery location. One or more powered conveyor
systems may
be provided on the delivery module for conveying the granular material.
Conveyance of
granular material may be, at various locations, at least partially assisted by
gravity, unassisted
by gravity, and/or conveyed against gravity.
[0070] In embodiments of the present invention, the delivery module may be
reconfigurable between a transportation configuration and an operational or
site
configuration. In the transportation configuration, the delivery module may be
configured as
a standard or over-length trailer, for example subject to one or more
predetermined sets of
legal and/or regulatory requirements, and/or other height, length, width
and/or weight
restrictions. In the operational configuration, the delivery module may be
configured having
a granular material reception area with surface area and capacity adequate for
receiving
granular material from up to a predetermined number of mobile storage modules.
The
delivery module may be configured, in the operational configuration, to have a
lower bearing
surface with a predetermined portion contacting ground, adequate for
supporting the weight
of the delivery module and granular material thereon against ground. Conveyors
may be
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stowed in the transportation configuration and deployed to cover or span a
greater surface
area in the operational configuration.
[0071] Figure 9 illustrates a top view of a delivery module 900 in accordance
with
embodiments of the present invention. As illustrated, the delivery module 900
comprises a
pair of main conveyors 910, 912 for receiving granular material from the
mobile storage
modules and conveying same to a discharge end 915. The delivery module 900 may
further
comprise or be operatively coupled to one or more discharge conveyors, for
example
conveyors 130 as illustrated in Figure 1.
[0072] As illustrated in Figure 9, the delivery module 900 comprises a trailer
chassis 905
upon which two main conveyors 910, 912 are mounted. Plural main conveyors may
be
provided for redundancy, to facilitate continued operation or failover in case
of failure of one
conveyor. Alternatively, a single conveyor may be provided, which may simplify
design and
in some cases provide increased conveyor surface area, or more conveyors may
be provided.
The trailer chassis 905 may be a rock-over chassis, or other suitable frame or
chassis. The
delivery module may be reconfigurable between a transportation configuration
and an
operational or site configuration. In the operational configuration, the
conveyors 910, 912
may be deployed outward relative to the transportation configuration. This
configuration, in
conjunction with a rock-over chassis, may facilitate deployment of the
conveyors 910, 912
close to ground and outboard of the trailer chassis 905 in the operational
configuration. In
some embodiments, the conveyors 910, 912 may be connected to the chassis 905
via a series
of laterally arranged sliding tubes spaced substantially evenly along the
length of each
conveyor. The sliding tubes may be deployed outward using one or more
hydraulic
actuators, for example. Figure 9 also illustrates location of semi-trailer
axles 925 and
hydraulics 930 operatively coupled to the sliding tubes for movement thereof,
thereby
facilitating deployment and stowage of the conveyors 910, 912.
[0073] In some embodiments, a main conveyor of the delivery module and an
associated
discharge conveyor may be associated via a common conveyor belt. The common
conveyor
belt may extend substantially horizontally over a first predetermined area
associated with the
main conveyor, to be situated substantially below the output ports of one or
more mobile
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storage modules stationed around the delivery module. The common conveyor belt
may
further extend at an angle over a second predetermined area associated with
the discharge
conveyor, to raise the granular material to a predetermined height for
discharge. In this
manner, granular material, such as proppant, may be conveyed from output ports
of the
mobile storage modules and elevated to a height suitable for discharge into
vehicular, or
otherwise, mounted receptacles, such as blender modules.
[0074] In some embodiments, such as illustrated in Figure 9, the delivery
module
conveyors 910, 912 may be carried upon a dedicated, custom configured semi-
trailer chassis
905. The chassis 905 may comprise a full-length rigid frame having, at a first
end 920, a
standard trailer kingpin and coupler structure, or other trailer coupling
components, and at a
second, discharge end 915 a set of one or more axles and/or suspension
assembly of the
semi-trailer. As mentioned previously, the chassis 905 may be a rock-over
chassis. When
disconnected from the road tractor, the first end 920 of the rock-over chassis
may be lowered
to ground, and the chassis lower surface may contact the ground, thereby
evenly distributing
load of the delivery module into the ground along the length of the rock-over
chassis. In
some embodiments, a suspension assembly may be located and oriented such that
by
deflating air springs thereof, the chassis 905 can be lowered into contact
with the ground to
form a full length bearing structure.
[0075] Figure 10 illustrates an end view of a discharge end of a delivery
module, in
accordance with embodiments of the present invention. As illustrated, the
discharge ends of
a pair of conveyors 910, 912 of the delivery module may be connected by a
discharge
manifold 1020 extending downwards and equipped with two discharge ports 1022,
1024.
The discharge manifold receives granular material from both left and right
conveyors 910,
912 and selectably provides the granular material to one or both of the two
discharge ports
1022, 1024. The manifold 1020 may comprise a configurable multiple orientation
gate or
other means for directing granular material from a selected one, or both of
the conveyors
910, 912 to a selected one, or both of the two discharge ports 1022, 1024. The
manifold
may thereby be configured to provide flow from one or more selected conveyors
to one or
more selected discharge ports, and/or to blend flow from each conveyor to a
selected
discharge port or both discharge ports. In some embodiments, the proportions
and amounts
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of material provided to each discharge port and/or from each conveyor may be
adjusted,
thereby facilitating finer control of mixing. Figure 10 further illustrates
chassis 925 and
wheels 1040 of the delivery module.
[0076] Figure 11 illustrates a rear/discharge end of a delivery module in both
a
transportation configuration 1100 and an operational configuration 1110, in
accordance with
embodiments of the present invention. The chassis 1120 may be pivotably
coupled with a
wheeled portion 1130 containing the rear axles and wheels of the delivery
module semi-
trailer, for example via a pin joint or other pivotable coupling. In the
transportation
configuration, the wheeled portion 1130 may be lowered to engage ground, for
example by
actuation of one or more hydraulic cylinders 1140, the chassis 1120 lifted off
of ground
during transport. A removable brace 1135 may be installed in a substantially
triangular gap
between the chassis 1120 and the wheeled portion 1130 for improved support
during
transport. In the operational configuration, the brace 1125 may be removed and
the wheeled
portion 1130 raised, for example by actuation of the one or more hydraulic
cylinders 1140,
and the chassis lowered to engage ground. This configuration facilitates
tilting retraction of
the axles for the operational configuration, thereby facilitating engagement
of the chassis
1120 with the ground for load distribution. Tilting and retraction of axles
may also be
provided for in one or more mobile storage modules, for facilitating
engagement of the frame
thereof with ground to facilitate load distribution.
[0077] In some embodiments, the present invention may be configured to
facilitate
prevention of proppant loss, for example due to loss of proppant from
conveyors or due to
overflow in event of conveyor failure. For example, embodiments of the present
invention
comprise one or more covers, such as non-rigid covers or tarps, which may be
deployed to
enclose regions through which granular material is conveyed. For example, each
main
conveyor and/or discharge conveyor of the delivery module may be fully or
partially
enclosed by a cover over its length. The conveyor cover may comprise apertures
at
predetermined locations for receiving material from the output ports and/or
discharge chutes
of the mobile storage modules. One or more covers, such as fitted non-rigid
cowls may be
provided between the apertures of the conveyor cover and the output ports,
with approximate
seal at cover interfaces. In this manner, environmental contamination, such as
rain or snow,
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may be restricted from entering the granular material as it is delivered from
the mobile
storage modules.
Set-up, Operation and Tear-down
[0078] Embodiments of the present invention are reconfigurable between
transportation
and operational configurations, thereby facilitating mobility, and relatively
quick set-up and
tear-down when compared with at least some prior art solutions. Each mobile
storage
module and delivery module may be hauled to a work site by a separate truck,
for example.
Embodiments of the present invention provide for a self-erecting, and
substantially self-
sufficient, system for storage and handling of proppant or other granular
material. In some
embodiments, the system may be set up on site within hours.
[0079] In some embodiments, the present invention may provide for storage and
delivery
capacity of suitable for projects requiring about 50,000 cubic feet of
granular material such
as proppant. For example, the system may comprise plural mobile storage
modules, each
configured for holding up to 5,000 cubic feet of granular material, which may
be discharged
by gravity to a delivery module. Ten mobile storage modules so configured may
thus
provide about 50,000 cubic feet of granular material. The rate at which
granular material
may be supplied may also scale with the number of mobile storage modules used,
subject to
capacity of the distribution module arrangement in use. More or fewer mobile
storage
modules may also be provided, thereby making the system scalable as required
by an
operation. Each delivery module may be capable of servicing up to a
predetermined number
of mobile storage modules. Thus, in some embodiments, plural delivery modules
may be
provided, end-to-end or in parallel, to satisfy operational requirements.
[0080] In embodiments of the present invention, one or more modules, such as
mobile
storage modules and delivery modules, may be powered by self-contained
hydraulic power
packs, or other appropriate sources of fluid or mechanical power. Each module
may be
powered by its own power pack, with power packs being interchangeable between
modules
in case of failure events. Each power pack may comprise a prime mover, such as
a
combustion engine, a hydraulic pump, a hydraulic reservoir and associated
filtering,
plumbing and control valves, and possibly other components configured together
for
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supplying hydraulic power. In some configurations, plural modules can operate
independently, but the hydraulic power packs may be configured to allow cross
connection
between modules or to auxiliary equipment as may be required. In some
embodiments, each
module having its own power pack may be operable independently. This reduces
requirements for external lifting equipment or power sources, which may not be
readily
available on site.
[0081] Figure 12 illustrates a partial top view of a system for handling
granular material in
accordance with the present invention. The system comprises a plurality of
mobile storage
modules 200a, 200b, 200c, 200d arranged around a delivery module 900. Each
mobile
storage module 200a, 200b, 200c, 200d comprises a discharge chute 250a, 250b,
250c, 250d,
respectively. A first pair of discharge chutes 250a, 250b are positioned
overtop of a first
conveyor 912 of the delivery module, and a second pair of discharge chutes
250c, 250d are
positioned overtop of a second conveyor 910 of the delivery module. During
normal
operation, the first pair of discharge chutes 250a, 250b discharge granular
material onto the
first conveyor 912, and the second pair of discharge chutes 250c, 250d
discharge granular
material onto the second conveyor 910. Granular material is then conveyed to a
discharge
end of the delivery module. A crossover conveyor 1240 may be provided as shown
should
the first conveyor 912 fail. The crossover conveyor 1240 may have a first end
which may be
oriented under the discharge chute 250a or another chute, and a second end
overtop of the
second conveyor. The crossover conveyor 1240 may thus be configured to convey
material
from the discharge chute 250a to the second conveyor 910, thereby bypassing
the first
conveyor 912 in the event of failure thereof. One or more crossover conveyors
may be
provided which may be oriented and/or re-oriented as needed between a selected
discharge
chute and a selected conveyor.
Uses
[00821 Embodiments of the present invention may be used for storing and
delivering
proppant for drilling by hydraulic fracturing, for example for oil and gas
drilling, shale
drilling, and the like. In accordance with some embodiments, the present
invention may be
configured to convey the proppant material, via the delivery module, to one or
more blender
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modules. The blender modules may receive and combine the proppant with water
and
possibly other chemicals to create slurry which is then provided to one or
more hydraulic
fracturing pumps for pumping into a well borehole for drilling.
[00831 In some embodiments, the present invention may be employed as a
material
storage and metering device for granular or flow-able materials other than
proppant, and/or in
applications other than well stimulation. For example, embodiments of the
present invention
may be employed to receive, store and convey a predetermined granular material
in
applications such as agriculture, in construction, road sanding and salting,
and the like. In
some embodiments, the present invention may be configured for water recovery
storage for
slick water fracking operations.
[00841 It is obvious that the foregoing embodiments of the invention are
examples and can
be varied in many ways. Such present or future variations are not to be
regarded as a
departure from the spirit and scope of the invention, and all such
modifications as would be
obvious to one skilled in the art are intended to be included within the scope
of the following
claims.
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