Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
PROPPANT STORAGE AND TRANSFER SYSTEM AND METHOD
[0001] Blank.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present invention relates to the oil and gas industry and, more
particularly, to the
transport and storage of proppant.
2. Description of Related Art
[0003] Hydraulic fracturing is the propagation of fractions in a rock layer
caused by the presence
of pressurized fluid. Hydraulic fractures may form naturally, in the case of
veins or dikes, or may
be man-made in order to release petroleum, natural gas, coal seam gas, or
other substances for
extraction. Fracturing is done from a wellbore drilled into reservoir rock
formations. The energy
from the injection of a highly-pressurized fracking fluid creates new channels
in the rock which
can increase the extraction rates and ultimate recovery of fossil fuels. The
fracture width is
typically maintained after the injection by introducing a proppant into the
injected fluid.
Proppant is a material, such as grains of sand, ceramic, or other
particulates, that prevents the
fractures from closing when the injection is stopped.
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100041 A dominant proppant is silica sand, made up of ancient weathered
quartz, the most
common mineral in the Earth's continental crust. Unlike common sand, which
often feels gritty
when rubbed. between the fingers, sand used as a proppant tends to roll to the
touch as a result of
its round, spherical shape and tightly-graded particle distribution. Sand
quality is a function of
both deposit and processing. Grain size can be a key factor, as any given
proppant must reliably
fall within certain mesh ranges, subject to downhole conditions and completion
design.
Generally, coarser proppant allows for higher flow capacity due to the larger
pore spaces
between grains. It may break down, however, or crush more readily under stress
due to the
relatively fewer grain-to-grain contact points to bear the stress often
incurred in deep oil- and
gas-bearing formations.
100051 Commonly, the proppant (e.g., the silica sand) is mined at a quarry and
loaded into
containers (e.g.., sand hoppers) for storage and subsequent transportation to
staging areas, well
sites, or the like. For example, the proppant may be loaded into a sand hopper
connected to a
locomotive to transport the sand hopper to a different location for subsequent
preparation and
loading of the proppant. The sand hopper may be unloaded at a staging area and
then loaded
onto pneumatic trucks for delivery to well sites. This process involves
several loading and
unloading steps for the proppant, thereby increasing cost, shrinkage, and
potentially hazardous
working environments. Accordingly, it is now recognized that improved
logistics for the storage
and delivery of proppant is desirable.
BRIEF SUMMARY OF THE INVENTION
100061 In an embodiment, a rail car for supporting and transporting one or
more containers
storing proppant therein includes a spine member extending from a first end to
a second end. of
the rail car, the spine member having a variable height that is ater at a
midpoint of the spine
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member than at the first end and at the second end. The rail car also includes
a bolster arranged
on a top surface of the spine member and extending laterally off of the spine
member in two
directions, the bolster having a greater width proximate the spine member than
at a distal end of
the bolster. Furthermore, the rail car includes a mounting platform positioned
on the distal end
of the bolster and having a container surface that receives the one or more
containers when
arranged thereon, the mounting platform extending vertically from the bolster
to position the one
or more containers above a top surface of the bolster when positioned thereon.
Moreover, the
rail car includes a locking assembly positioned on the mounting platform to
engage the one or
more containers when positioned thereon, the locking assembly securing the one
or more
containers to the rail car when moved from an unlocked position to a locked
position,
100071 in a further embodiment a proppant storage and transportation system
includes a plurality
of containers arranged in a side-by-side configuration. .Each container of the
plurality of
containers includes a pair of side walls, a pair of end walls, a top, a
bottom, and inclined surfaces
extending in a downward direction from the side walls and the end walls toward
a discharge
opening in the bottom to direct proppant stored therein out of the container
via the discharge
opening. The system also includes a rail car. The rail car includes a spine
member extending
from a first end to a second end, the spine member having a variable height
that is greater at a
midpoint than at the first and second ends. 'The rail car also includes a
plurality of bolsters
arranged along a length of the spine member, the plurality of bolsters
extending laterally outward
from the spine member. Also, each bolster of the plurality of bolsters has a
distal end that is
narrower than a proximal end. Furthermore, each bolster is arranged such that
at least one
container of the plurality of containers is in contact with at least one
bolster of the plurality of
bolsters when the at least one container is positioned on the rail car. The
rail car also includes
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one or more mounting platforms arranged on the distal end of each bolster of
the plurality of
bolsters, the one or more mounting platforms extending vertically above a. top
surface of each
bolster of the plurality of bolsters such that the at least one container
arranged thereon is not in
contact with the top surface of each bolster of the plurality of bolsters.
100081 In an embodiment a method for filling and transporting proppant
containers includes
filling the proppant container through an opening in a top wall, the proppant
container having
inclined surfaces that direct the proppant therein toward a discharge opening.
The method also
includes positioning the proppant container onto a rail car, the rail car
having one or more
bolsters arranged transverse to a spine member. The one or more bolsters
include mounting
platforms to receive the container and to elevate the container above a top
surface of the one or
more bolsters. The method fiuther includes transporting the proppant
container, via the rail car,
to a staging area. The method includes unloading the proppant container from
the rail car and
arranging the proppant container in a stacked configuration with one or more
other proppant
containers.
BRIEF DESCRIPTION OF THE FIGURES
[00091 Figure 1 is a perspective view of an embodiment of a container for the
transport and
storage of proppant, according to aspects of the present disclosure.;
100101 Figure 2 is a cross-sectional elevation view of the container of FIG.
1, according to
aspects of the present. disclosure;
100111 Figure 3 is a side elevation view of the container of FIG. 1, according
to aspects of the
present disclosure;
100121 Figure 4 is an end elevation view of the container of FIG. I, according
to aspects of the
present disclosure;
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100131 Figure 5 is a bottom view of the container of FIG. I, according to
aspects of the present
disclosure;
100141 Figure 6 is a perspective view of an embodiment of a rail car for
receiving and supporting
the container of FIG. 1, according to aspects of the present disclosure;
100.151 Figure 7 is a side elevation view of the rail car of FIG. 6 having
four containers
positioned thereon, according to aspects of the present disclosure;
[00161 Figure 8 is a top plan view of the rail car of FIG, 6, according to
aspects of the present
disclosure;
100171 Figure 9 is a further top plan view of the rail car of FIG. 6,
according to aspects of the
present disclosure;
100181 Figure 10 is a cross-sectional view taken along line 10-10 of FIG. 8,
according to aspects
of the present disclosure;
[00191 Figure II is a perspective view of an embodiment of the container of
FIG. 1 positioned
relative to a locking mechanism of the rail car, according to aspects of the
present disclosure;
[00201 Figure 12 is a schematic view of the rail car of FIG. 6 coupled to an
engine and
positioned on a rail section, according to aspects of the present disclosure;
100211 Figure 13 is a perspective view of an embodiment of a system for the
delivery of
.proppant, according to aspects of the present disclosure; and
100221 Figure 14 is a flow chart of an embodiment of a method for loading and
transporting
proppant in a container.
DETAILED DESSCRIIMON OF THE INVENTION
100231 The foregoing aspects, features, and advantages of the present
invention will be further
appreciated when considered with reference to the following description of
embodiments and
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accompanying drawings. In describing the embodiments of the invention
illustrated in the
appended drawings, specific terminology will be used for the sake of clarity.
However, the
invention is not intended to be limited to the specific terms used, and it is
to be understood that.
each specific term includes equivalents that operate. in a similar manner to
accomplish a similar
purpose.
100241 When introducing elements of various embodiments of the present
invention, the articles
"a," "an," "the," and "said" are intended to mean that there are one or more
of the elements. The
terms "comprising," "including," and "having" are intended to be inclusive and
mean that there
may be additional elements other than the listed elements. Any examples of
operating parameters
and/or environmental conditions are not exclusive of other
parameters/conditions of the
disclosed embodiments. Additionally, it should be understood that references
to "one
embodiment", "an embodiment', "certain embodiments," or "other embodiments" of
the present
invention are not intended to be interpreted as excluding the existence of
additional embodiments
that also incorporate the recited features. Furthermore, reference to terms
such as "above,"
"below," "upper", "lower", "side", "front," "back," or other terms regarding
orientation are made
with reference to the illustrated embodiments and are not intended to be
limiting or exclude other
orientations.
100251 In hydraulic fracturing operations, a large amount of proppant is
utilized, and it can be
difficult to effectively store the proppant at the fracturing sites.
Additionally, various difficulties
may arise while transporting the proppant to a desired location. Proppant may
be hauled to the
desired locations on the back of trucks and clumped onsite. Under such
circumstances, the
proppant is exposed to adverse weather conditions. This may degrade the
quality of the proppant
during its storage. Additionally., the maintenance of proppant in containers
at the hydraulic
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fracturing site requires a large capital investment in storage facilities.
Typically, the unloading of
such storage facilities is carried out on a facility-by-facility basis. As
such, there is a need. to be
able to effectively transport. the proppant to and store the proppant in a
desired location adjacent.
to the hydraulic fracturing location.
100261 With the development and acceptance of the well stimulation methodology
known as
"hydraulic fracturing," a unique logistics Challenge has been created in
delivering the massive
quantities of proppant from domestic sand mines to the wellhead. This
logistics challenge affects
every stakeholder up-and-down the logistics chain. In particular, this
includes sand mine owners,
railroads, trans-loading facilities, oil-field service companies, trucking
companies and
exploration and production companies. As such, a need for facilitating the
ability to quickly and
inexpensively off-load proppant from rail cars so as to enable railroads to
improve the velocity;
turn-around, and revenue-generating capacity of the rail-car fleet is present
in the industry.
[00271 Furthermore, limited storage at trans-loading facilities has severely
limited many of the
current facilities' ability to operate efficiently. Most trans-load facilities
are forced to off-load
rail hopper cars by bringing in trucks (i.e. pneumatics) along the rail
siding, and conveying sand
directly from rail to truck. This requires an intense coordination effort on
the part of the
trans-loader as well as the trucking community. Long truck lines are
commonplace, and
demurrage fees (i.e. waiting time charged by trucking companies) amount to
hundreds of
millions of dollars nationwide. As such, throughput of these trans-loading
terminals is reduced
greatly, which costs the terminal meaningful revenue.
[00281 Additionally, trans-load terminal locations are not able to move from
one area of the
shale pay to another, and a potential loss of the investment in such immobile
silos can often scare
investment capital away from these -types of future projects so as to further
exacerbate the
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logistics chain problem. As such, a need has developed for a portable,
inexpensive storage and
delivery solution for proppant
100291 Furthermore, service companies (such as fracturing companies.) are held
captive by the
current proppant delivery process. This is the result; in part, of inefficient
trans-load facilities and
pneumatic (bulk) truck deliveries. A service company cannot frac a well if it
does not have a
supply of proppant. Thus, pressure pumps, coiled tubing, and other well
stimulation equipment
sits idle due to the lack of required proppant at the well-site. "Screening-
Out" or running out of
proppant may occur at well locations due to the lack of control over what is
happening up-stream
in the proppant logistics chain.
100301 Additionally, as will be -described below, modular storage containers
may be utilized to
store and transport proppant from a sand quarry, a loading terminal, or the
like. These modular
containers may include ramped sections to facilitate the unloading of proppant
from a
controllable opening (e.g., a discharge opening) at a bottom of the container.
However, an
improper arrangement of plates (e.g., the ramped sections, funnel section)
extending to the
discharge opening of a container creates conflicting problems in the delivery
of proppant. For
example, if the funnel is at an angle that is too great, then it will occupy
too much space within
the interior of the container. As such, the desired ability to transport
between 45,000 pounds and
48,000 pounds of proppant is compromised. Although the steep inclination of
the funnel allows
for the proper discharge of all of the proppant from the interior of the
container, the containers
are found to be unable to contain the desired amount of proppant. On the other
hand., if the angle
of the funnel is too shallow, then the proppant cannot be discharged properly
from the bottom
discharge opening. It is found that a certain amount of proppant will be
retained within the
interior volume of the container after discharge. As such, the full amount of
the proppant cannot
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be delivered, by a conveyor, to the wellsite. Additionally, if the angle of
the funnel is too
shallow, certain bridging effects will occur with the proppant within the
container. As such, this
could block the flow of proppant properly moving outwardly of the discharge
opening. Although
a shallow angled funnel allows the container to receive the desired amount of
proppant, the
shallowness of the angle of the funnel works against the ability of the
container to properly
discharge the desired amount of proppant As such, a properly configured funnel
so as to
maximize the amount of proppant contained within the container while, at the
same time,
assuring that all of the proppant within the container will be properly
discharged by gravity
discharge onto a conveyor is desirable to facilitate a modular proppant
storage and transportation
system.
100311 Embodiments of the present disclosure include a rail car for receiving,
supporting, and
transporting one or more containers having proppant stored therein. The rail
car includes a spine
member extending from a first end to a second end and having a variable
height. The variable
height of the spine member is greater toward the center of the rail car,
thereby providing
additional strength and stability to the rail car when supporting a load
(e.g., the containers).
Moreover, the rail car includes one or more bolsters positioned along the
length of the rail car.
The bolsters extend from the spine member radially outward toward support
rails perpendicularly
positioned about the rail car. The bolsters include one or more mounting
platforms at an end
distal from the spine member to receive and support the containers. In.
certain embodiments, the
mounting platforms include a container surface to receive a bottom of the
container and to
elevate the container above a top surface of the bolster. Further, the one or
more mounting
platforms each include a locking assembly to secure the containers to the
bolsters. For example,
the locking mechanisms may align with an opening or recess in the container
when the container
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is positioned thereon. As a result, the one or more containers may be secured
to the rail car for
subsequent transportation_
100321 Moreover, embodiments of the present disclosure are directed toward a
method for
loading and transporting proppant into containers. For example, the method
includes loading the
proppant into the containers at the mine and then positioning the containers
onto a rail car
configured to support one or more containers. As will be described in detail
below, the rail cars
may be specially configured to support approximately 260000 pounds while still
maintaining the
structural integrity and mobility necessary to travel along traditional
railways, rail yards, and
bridges. The container may be transported to a staging area and then
positioned onto a truck for
transportation to the well site. At the well site, the container may be
removed from the truck,
stacked, and then emptied for utilization in a wellbore. Accordingly, the
method disclosed
herein may be utilized to reduce the number of handling steps proppant
undertakes while being
transported from a mine to a well site.
100331 Turning to FIG. I, a perspective view of a prom= container 10 is shown.
The container
includes a storage body 12 formed at least partially by a top wall 14, a pair
of side walls 16,
18, and a pair of end walls 20, 22. Moreover, the container 10 includes a
bottom discharge
opening (not shown) located below the pair of side walls 16, 18 and the pair
of end walls 20, 22.
In the illustrated embodiment, a hatch 24 is hingedly mounted to the top wall
14 so as to cover
one or more openings in the top wall 14. As will be described below, the hatch
24 moves
between an open position and a closed position to enable access to an interior
volume of the
storage body 12. For example, the hatch 24 may be moved to the open position
while the
container 10 is loaded with proppant and moved to the closed position during
transportation and
discharge.
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100341 In the illustrated embodiment, the top wall 14 is a generally planar
surface. In other
embodiments, however, the top wall 14 may include one or more surfaces
positioned as various
angles. For example, the top wall 14 may include a generally planar surface
connected to
surfaces having a generally downward slope on each side. As shown, the hatch
24 is connected
by one or more hinges 26 to the top wall 14. The hinges 26 facilitate the
transition of the hatch
24 from the open position to the closed position. Latches 28, 30 are utilized
to secure the hatch
24 to the top wall 14 while the hatch 24 is in the closed position. That is,
the latches 28, 30 are
utilized to secure the hatch 24 over the one or more openings. In certain
embodiments, the hatch
24 includes a liner or gasket to form a liquid-tight seal over the one or more
openings formed in
the top wall 14. The liner or gasket may interface with a. lip (not pictured)
positioned proximate
the top wall 14. Accordingly, the container 10 may substantially isolate the
proppant within the
interior volume from the outside environment, thereby maintaining the
integrity of the proppant
by blocking and/or preventing moisture, dust, and other contaminants from
entering the container
10. Moreover, the liquid-tight seal blocks silica dust from exiting the
container 10 when the
hatch 24 is in the closed position.
100351 In the illustrated embodiment, the side walls 16. 18 and the end walls
20, 22 form a
substantially rectangular configuration at least partially finding the
interior volume of the storage
body 12. As shown, a frame 32 is positioned about exterior surfaces of the
side walls 16, 18 and
the end walls 20, 22. While the illustrated embodiment is a perspective view
and illustrates the
frame 32 on the side wall 16 and the end wall 20, it is appreciated that the
frame 32 extends
about each side of the container 10 in a substantially similar configuration.
The frame 32
includes horizontal members 34 and vertical members 36 arranged in a
substantially cage-like,
cross-hatched, checkered pattern. As a result, in the illustrated embodiment,
horizontal members
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34 and the vertical members 36 form substantially rectangular sections on the
exterior surfaces of
the walls 16, 18, 20, 22. It should be appreciated, however, that in certain
embodiments the
frame 32 may include only horizontal members 34, only vertical members 36, or
different
arrangements of horizontal members 34 and vertical members 36 on the walls 16,
18, 20, 22. In
certain embodiments, the horizontal members 34 and the vertical members 36 are
formed from
square tubing bears against the outer surfaces of the respective walls 16, 18,
20, 22. As such, the
frame 32 contributes to the structural integrity of the container 10. As that,
the frame 32
prevents the proppant stored within the container 10 from driving the walls
16, 18, 20, 22
outward, thereby causing bulging of the walls 16, 18, 20, 22. In this manner,
large loads of
proppant (e.g., between 40,000 and 48,000 pounds) may be placed within the
interior volume of
the container 10 while maintaining the structural integrity of the container
10. Moreover, it is
appreciated That in other embodiments larger loads of proppant may be placed
into the interior
volume of the container 10.
100361 In the illustrated embodiment, the frame 32 includes corner posts 38 to
further enhance
the structural integrity of the container 10. As shown, the horizontal members
34 abut the corner
posts 38. The corner posts 38 are positioned at the intersection between the
sidewalls 16, 18 and
the end walls 20,. 22 to provide structural integrity to the substantially 90
degree intersection
between the sidewalls 16, 18 and the end walls 20, 22. The corner posts 38
extend to a. bottom
40. As will be described below, the discharge opening is positioned in the
bottom 40.
1,00371 The illustrated container 10 further includes a ladder 42 coupled to
the sidewall 16. The
ladder 42 extends vertically upwards front the bottom 40 to the top wall 14,
thereby facilitating
access to the top wall 14. For example, an operator may climb up the ladder
onto the top wall 14
to move the hatch 24 from the closed position to the open position.
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100381 FIG. 2 is a cross-sectional elevation view of the container 10. In the
illustrated
embodiments, frame 32 is positioned on the exterior surface of the side walls
16, 18 and the
corner posts 38 extend toward the bottom 40. As shown, the hatch 24 is in the
dosed position on
the top wall 14 and an -interior volume 50 of the storage body 12 is at least
partially defined by
the side walls 16, 18 and the end wall 22.
100391 The container 10 includes gussets 52 coupled to and supporting
respective inclined
surfaces 54, 56 (e.g., ramps). The gussets 52 have a top surface 58 coupled to
a bottom surface
60 of the respective inclined surfaces 54, 56 such that the downward incline
of the gussets 52 is
substantially equal to the downward incline of the inclined surfaces 54, 56.
As shown, the
gussets 52 extend laterally inward from the frame 32 toward a discharge
opening 62. In the
illustrated embodiments, the gussets 52 include holes 64 particularly selected
to redact the
weight of the gussets 52 (and thereby reduce the weight of the container I 0)
while providing
sufficient structural strength to support the inclined surfaces 54, 56. As
will be appreciated,
multiple gussets 52 may be utilized to support the inclined surfaces 54, 56.
For example, a
gusset (not shown) may support an inclined surface 66 extending from the end
wall 22.
[00401 The inclined surfaces 54, 56, 66 (e.g., side plates, end plates) form a
discharge area 68
having a funnel shape to direct proppant from the interior volume 50 'toward
the discharge
opening 62. The angle of the side plates and end plates helps to facilitate
substantially complete
discharge of the material (e.g., proppant) within the container through the
discharge opening 62.
Yet, the angle of the inclined surfaces is particularly selected such that a
maximum amount of
proppant can be contained within the interior volume of the container 10. In
certain
embodiments, this volume will be between 45,000 pounds and 48,000 pounds of
proppant. In
particular, the angle defined by the inclined surfaces 55, 56 and the gussets
52, can be at an angle
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of greater than 25 with respect to the horizontal. In particular, the pair of
end plates can extend
in an angle of less than 37' with respect to the horizontal. In an embodiment
of the present
invention, the end. plates extend at an angle of approximately 31' with
respect to horizontal..
Similarly, the inclined surface 66 also can extend at an angle of greater than
25 with respect. to
horizontal. The pair of side plates can extend at an angle of greater than 30
with respect to
horizontal_ In an embodiment the present invention, each of the pair of side
plates extends at an
angle of 38 with respect to the horizontal. It is appreciated that the
inclined surfaces may be
arranged at an angle particularly selected to facilitate drainage while
maximizing the interior
volume 50. For example, in embodiments, the angle may be between 20 and 50
degrees, 30 and
60 degrees, or the like.
[00411 As shown in FIG. 2, sleeves 70 are arranged at the bottom 16. The
sleeve 70 may be
sized to receive the forks of a forklift truck, for example. As will be
described in detail below,
the forklift truck may be utilized to lift and move the container 10 along the
supply change as
proppant to stored and transported from a mine to a well site.
100421 FIG. 3 is a side elevation view of the container 10 illustrating an
embodiment of the
sidewall 18. As described above, the frame 32 includes the horizontal members
34 and the
vertical members 36 extending in a cross-batch manner to provide structural
support to the
storage body 12. Moreover, the discharge area 68 is positioned proximate the
gussets 52 to
facilitate drainage of the proppant from the interior volume 50.
100431 FIG. 4 is a side elevation view of the container 10 illustrating an
embodiment of the end
wall 22. In the illustrated embodiment, the frame 32 forms the cross-hatch
pattern to provide
structural, support to the storage body 12. However, as described above, in
other embodiments
the frame 32 may include other configurations such as only having the
horizontal members 34 or
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only having the vertical members 36. Moreover, as shown, the gussets 52 extend
inwardly from
the exterior of the container 10 toward. the discharge opening 62 such that
the gussets 52 support
the inclined surfaces of the discharge area 68. Accordingly, the container 10
is configured to
support, transport, arid discharge proppant.
100441 FIG. 5 is a bottom view of an embodiment of the container 10. In the
illustrated
embodiment, a reinforcing plate 80 surrounds a perimeter of the discharge
opening 62. As will
be appreciated, while the discharge opening 62 is substantially rectangular in
the illustrated
embodiment, the other embodiments the discharge opening 62 may be circular or
any polygonal
shape to facilitate draining the proppant from the interior volume of the
container 10. The
reinforcing plate 80 enhances the structural integrity of the discharge
opening 62 by coupling the
inclined surfaces (e.g., inclined surface 54, 56, 66) together, Moreover, the
discharge opening 62
includes a gate 82. The gate 82 may be selectively opened and closed to enable
the discharge of
proppant from the container 10. For example, the gate 82 may be hydraulically
actuated.
mechanically actuated, electronically actuated, or the like.
[0045i Moreover, the frame 32 is shown substantially surrounding the perimeter
of the storage
body 12. in the illustrated embodiment, the corner posts 38 include openings
84 configured to
receive one or more fasteners to mechanically secure the container to a stand,
structure, cradle,
truck, or railroad. car. The illustrated openings 84 are substantially
rectangular and include one
or more receptacles to couple the container 10 to the stand, structure,
cradle, truck, railroad car,
or the like.
[00461 FIG. 6 is a perspective view of an embodiment of a rail car 90
configured to support
and/or transport at least one container 10. As shown, the rail car 90 includes
support rails 92
extending about a periphery of the rail car 90. The support rails 92 are
positioned to add
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structural integrity to the rail car 90 to facilitate handling of the one or
more containers 10. As
will be described below, in certain embodiments, the rail car 90 has four
containers 10 positioned
in a side-by-side configuration &ono. a length 94 of a load section 96 of the
rail car 90. in certain
embodiments, the containers 10 can hold approximately 48,000 point& of
proppant, thereby
having a weight of approximately 54,000 to 58,000 pounds. Accordingly, the
rail car 90 is
designed to support the weight of up to four containers 10, or approximately
216,000 pounds to
232,000 pounds by disturbing the weight substantially equally across the
trucks 98.
[00471 The rail car 90 includes the trucks 98 which interact with rails (not
pictured) to facilitate
movement of the rail car 90. The trucks 98 engage a weight management system
100 which
includes one or more springs 102 to extend and/or compress to accommodate
loads placed on the
rail car 90. For example, the springs 102 are positioned proximate to strut
members 104 coupled
to the trucks 98. As a load is placed on the rail car 90, the springs 102
compressõ thereby
absorbing at least a portion of the load placed on the rail car 90. As a
result, a greater quantity of
weight may be placed on the rail car 90.
[00481 The illustrated rail car 90 is a "spine car" having an elongated spine
member 106 oriented
along a rail car length 108. As will be described in detail below, the spine
member 106 has a
variable height (e.g. elevation relative to the ground) at a center portion of
the spine member
106. In other words, the height of the spine member 106 may be substantially
uniform and then
change near the mid portion of the spine member 106 and then return to being
substantially
uniform. The spine member 106 includes reinforcement at the sections having a
changing
height, thereby further increasing the structural integrity and support
capabilities of the rail car
90.
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100491 As shown, the rail car 90 includes bolsters 110 transversely mounted 10
the spine member
106 and radially outward from the spine member 106 toward the support rails
92. In the
illustrated embodiments, the bolsters 110 are coupled to the spine member 10o
at a proximal end
112 and to the support members 104 at a distal end 114. Moreover, as will be
described below,
the bolsters 110 have a variable width along a length 116 of the bolsters 110.
In other words, the
width of the bolsters 110 is narrower at the distal end 114 than at the
proximal end 112. Varying
the width of the bolsters 110 improves the structural support and integrity of
the bolsters 110,
and thereby the rail car 90. For example, increasing the width of the bolsters
110 at the proximal
end 112 increases the surface area of the bolsters 110 that contacts the spine
member 106, which
reduces the pressure at the connections (e.g., the welded connections) between
the bolsters 110
and the spine member 106.
[00501 The bolsters 110 also include mounting platforms 118 at respective
distal ends 114. The
mounting platforms 118 include locking assemblies 120 which couple to and
secure the
containers 10 to the rail car 90. For example, in certain embodiments, the
bolsters 110 include
two mounting platforms 118, each having a respective locking assembly 120. As
a result, certain
bolsters 110 of the rail car 90 may support two containers 10 during
transportation.
100511 The rail car 90 also includes platforms 12.2 at first and second ends
of the rail car 90. The
platforms 122. are arranged such than an operator may stand on the platforms
122 to secure the
rail car 90 to adjacent cars via couplers 124 positioned at the first and
second ends of the rail car
90.
1005211 FIG. 7 is a side elevation view of the rail car 90 having four
containers 10 positioned in a
side-by-side configuration alone the length 108 of the rail car 90. As shown,
the containers 10
are substantially symmetrical about a midpoint 130 of the rail car 90, thereby
distributing the
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weight across the trucks 98. Centering the weight substantially above the
midpoint of the rail car
90 also improves the handling and transportation properties of the rail car
90. For example, the
center of gravity of the rail car 90 is positioned in a location having
substantially equal support.
on each side of the midpoint 130. As a resuh, as the rail car 90 is pulled
along tracks, turns or
curvatures in the track can be accommodated without sacrificing the speed at
which the rail cars
90 can be moved. Moreover, as the rails cars 90 are pulled up elevation
changes, the likelihood.
of the rail cars 90 shifting and/or sliding is substantially decreased because
of the positioning of
the center of gravity along the length 108 of the rail car 90.
100531 As described above, the height (e.g., elevation) of the spine member
106 increases at
approximately the midpoint 130. For example, a first spine member height 132
at a first end 134
is less than a second spine member height 136 at the midpoint 130. Moreover, a
third spine
member height 1.38 at a second end 140 is less than the second spine member
height 136 and
substantially equal to the first spine member height 132. As shown, a
transition 142 between the
first and second spine member heights 132, 136 includes an inclined section
144 and a transition
146 between the second and third spine member heights 136, 138 also includes
an inclined
section 148. As will be appreciated, the inclined sections 144, 148
redistribute the forces acting
on the spine member 106 along their lengths, thereby enabling the spine member
106 to
transition between the heights. Moreover, by having a larger second spine
member height 136,
the spine member 106 can handle a larger force from the weight on the rail car
90 because the
larger cross-sectional area is less prone to bending and/or deformation than a
smaller cross-
sectional area. Furthermore, the substantially smooth transitions 142, 148
along the inclined
sections 144, 148 facilitates improved force transfer than a sharp transition
and maintains the
structural integrity of the spine member 106 along the length 108.
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100541 In the illustrated embodiment, the spine member 106 further includes
reinforcing
structures 150 located at various locations along the length 108. In other
words, the reinforcing
structures 150 are strategically located at areas alma the length 108 where
force transfer is likely
to occur. For example, the reinforcing structure 150a is positioned at the
transition 142, the
reinforcing structure 150b is positioned at the midpoint 130, and the
reinforcing structure 150c is
positioned at the transition 146. Moreover, as will be described below, the
bolsters 110 and the
mounting platforms 118 of the bolsters 110 are also positioned proximate the
reinforcing
structures 150.
100551 In certain embodiments, the reinforcing structures 150 may include
cross-bracing,
gussets, or the like to improve the structural integrity of the spine member
106 while also
facilitating the height change of the spine member 106. For example, the
reinforcing structures
150 may include cross-bracing positioned at approximately the center of the
transitions 142, 146.
The cross-bracing may absorb at least a portion of the force exerted on the
transitions 142, 146
by the containers 10. Moreover, in certain embodiments, the reinforcing
structures 150 may
extend radially outward toward the support rails 92, thereby further improving
the structural
integrity of the spine member 106. For example, the reinforcing structures 150
may be gussets
that couple the spine member 106 to the support rails 92. Accordingly, the
reinforcing structures
150 can enable the overall weight. of the rail car 90 to be reduced because
the spine member 106
has the variable height, thereby decreasing the total amount of material
utilized by the spine
member 106.
[00561 FIG. 8 is a top plan view of an embodiment of the rail car 90 having
the bolsters 110
coupled to the spine member 106 and extending radially outward toward the
support rails 92. In
the illustrated embodiment, the bolsters 110 include cross members 160
transversely mounted to
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the spine member 106õAs shown, the cross members 160 extend laterally off of
the spine
member and extend radially outward toward the support rails 92. Further, in
the illustrated
embodiment, top plates 162 mount to the spine member 106 on opposite sides of
the cross
members 160. In certain embodiments, the top plates 16.2 cover the cross
members 160. That is,
the top plates 162 may include slots or recesses to receive the cross members
160 and to mount
to opposite sides of the cross members 160.
[00571 As described above, a width 164 of the bolsters 110 (e.g., the top
plates 162) is greater at
the proximal end 112 than at the distal end 114. For example, a first bolster
width 166 is greater
than a second bolster width .168. Moreover, the bolsters 110 include a bolster
transition 170
between the first bolster width 166 and the second bolster width 168. As
described below with
respect to the transitions 142, 146, the bolster transition 170 facilitates
distribution of the forces
acting on the bolsters 110 over a larger surface area at the spine member 106.
Accordingly, the
pressure distributed over the spine member 106 is decreased. Further, in the
illustrated
embodiment, the first and second bolster widths 166, 168 are greater than a
cross member width
17.2. That is, the cross member 160 is substantially contained within the
bolster 110 by the top
plate 162.
100581 In the illustrated embodiment, the bolsters 110 are arranged in a
spaced relationship along
the length 108 of the spine member 106. For example, in the illustrated
embodiment, the
bolsters 110 are substantially aligned with the reinforcement structures 150.
However, in other
locations, the bolsters 110 may be positioned away from the reinforcement
structures 150. In
this manner, the bolsters 110 are spaced apart such that the mounting
platforms 118 are
positioned at intervals that enable containers 10 to couple to the rail car
90. For example, the
mounting plattbrms 118 and the locking assemblies 120 may interact with the
openings 84 in the
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corner posts 38 of the container 10. As a result, the bolsters 110 are
arranged such that the
locking assemblies 120 align with the containers 10 when the containers are
arranged in a side-
by-side configuration on the rail car 90.
100591 FIG. 9 is a top plan view Of an embodiment of the rail car X. It is
noted that several
features have been removed for Clarity. For example, in the illustrated
embodiment, the trucks
98 have been removed. As described above, the bolsters 110 are arranged in a
spaced apart
relationship along the length 108 of the spine member 106. In the illustrated
embodiment, there
are three bolsters 110, however, in other embodiments, there may be more or
fewer bolsters 110.
For example, the rail car 90 may include two bolsters 110 and be configured to
carry three rail
cars. Moreover, in other embodiments, the rail car 90 may include I, 2, 5, 6,
7, 8, 9, 10, or any
other suitable number of bolsters 110 to facilitate transportation of the
containers 10.
Furthermore, as shown in the illustrated embodiment, locking support members
180 are arranged
on the first and second ends 134, 140 of the rail car 90. The locking support
members 180 are
coupled to the spine member 106 and extend radially outward toward the support
rails 92 in the
same manner as the bolsters 110. Moreover, the locking support members 180
include the
mounting platform 118 and the locking assembly 120. The locking support
members 180 are
positioned proximate the platforms 122 and correspond to the bolsters 110 to
enable the
containers 10 to be positioned on rail car 90.
100601 In the illustrated embodiment, the mounting platfbrms 118 are arranged
on the distal end
114 of the bolsters 110 and the locking support members 180 approximately 8 to
9 feet from the
corresponding locking support members 180 on the opposite end of the bolsters
110. As such,
the rail cars 90 maintain a standardized width and can be transported on
commercial railroads
across the United States and in other countries. For example, limiting the
width of the rail car 90
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to approximately the width of the containers 10 enables the rail car 90 to
pass through tunnels
and conventional rail yards without modifications to existing infrastructure.
Furthermore,
because the width of the rail cars 90 is approximately as wide as the
containers 10, the amount of
material utilized to form. the rail cars 90 may be reduced, thereby further
reducing the overall
weight of the rail cars 90, which as will be described below, enables the rail
cars 90 to carry
several containers 10 (e.g., four containers) over existing infrastructure,
such as bridges,
economically and quickly without. utilizing multiple deliveries due to train
length and weight
concerns.
100611 The illustrated rail car 90 includes a first section 182, a second
section .184, a third
section 186, and a fourth section 188. Each section 182, 184, 186, 188
corresponds to and
receives a container 10. For example, with respect to the first section 182, a
first container 10a
engages the locking assemblies 120 arranged on the locking support member 180
at the .first end
134 and the locking assemblies 120 on the first bolster 110a arranged on the
spine member 106.
Further, a second container 10b engages the locking assemblies 120 arranged on
the first bolster
110 and the locking assemblies 120 on a second bolster 11%. In this manner,
four containers
I Oa, .10b, 10c, 10d may be positioned along the rail car 90 because adjacent
mounting platforms
118 and locking mechanism 120 are arranged to accommodate up to two containers
per bolster
110, in the illustrated. embodiment.
100621 FIG. 10 is a cross-sectional view of the bolster 110 taken along line
10-10 of FIG. 8. In.
the illustrated embodiment, the cross member 160 has a variable height (e.g.,
elevation,
thickness) from the distal end 114 to the proximal end 112. In other words,
the thickness of the
cross member 160 increases closer to the spine member 106 (e.g., the thickness
proximal to the
spine member 106 is greater than the thickness distal from the spine member
106). The cross
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member 160 includes a transition 200 that represents the change in thickness
along the length of
the cross member 160. As described above, the transition facilitates the
distribution of force
along the length of the cross member 160 toward the spine member 106. While
not pictured in
the .illustrated embodiment, in certain embodiments, the top plates 162 may
also include a
variable height and a transition. However, in other embodiments, the top
plates 162 may have a
uniform thickness.
100631 Further illustrated in FIG. 10 is the mounting platform 118. As shown,
the mound=
platform extends vertically Above a top surface 202 of the cross member 160.
in operation, the
containers 10 are positioned on the mounting platforms 118 and rest on the
container surface
204. The locking assembly 120 mounted on the mounting platform 118 extends
into the opening
84 in the corner posts 38, and is activated to lock the container 10 into
place on the mounting
platform 118. In this manner, the container 10 may be coupled to the rail car
90 at four contact:
points, thereby blocking movement in at least 6 directions (e.g., up, down,
left, tight, front,
back). Moreover, the four contact point locks also block twisting or turning
of the containers 10.
As mentioned above, the securement of the containers 10 to the rail car 90,
coupled with the
designed low center of gravity to facilitate coming and movement, enables the
rail car 90 to
transport multiple containers 10 (e.g., four containers) while distributing
the weight evenly
across the rail car 90. Moreover, the arrangement of the containers 10 on the
rail car 90 enables
the rail cars 90 to stay within regulatory restrictions for weight, height,
and length for travel over
bridges and through rail yards. As a result, more containers 10 may be shipped
with a smaller
trail of rail cars 90 and without special permitting or routing to comply with
regulations.
100641 FIG. 11 is a perspective view of the container 10 being aligned with
the locking assembly
120. It is appreciated that features have been removed from FIG. 11 for
clarity. As shown, the
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corner post 38 of the container 10 is substantially aligned with the mounting
platform 118 such
that the locking assembly 120 will engage the opening 84 of the comer post 38
when the bottom
of the container 10 moves into contact with the container surface 204. As
shown, the
arrangement of the mounting platform 118 and the locking assembly 120 is
particularly selected
to engage the containers 10 in one position (e.g., a position that enables the
locking assembly
120 to engage the corner posts 38). For example, the locking assemblies 120
may be arranged.
such that the forks of a forklift can engage the container 10 and position the
container 10 onto the
rail car 90_ As such, improper loading is blocked because if the container 10
were loaded in such
a manner that the container 10 could not contact the container surface 204,
the container 10
would not be locked to the rail car 90. When the container 10 is seated on the
container surface
204, the locking assembly 120 is engaged and moved from an unlocked position
to a locked
position.. The locked position secures the container 10 to the rail car 90,
thereby preparing the
container 10 for transport. It is appreciated that a variety of locking
mechanisms may be utilized
to secure the container 10 to the rail car 90. For example, the locking
assembly 120 may include
twist locks, cable tie downs, tongue and groove fasteners, or the like.
[00651 FIG. 12 is a top view of rail cars 90 transporting the containers 10
along a section of rail
210. As described above, the rail cars 90 are configured to enable an
arrangement of the
containers 10 along a length 108 to substantially center the weight over the
midpoint 130. As a
result, the center of tuavity of the rail cars 90 is balanced, thereby
enabling the rail car 90 to
handle a large load (e.g., between approximately 216,000 pounds to 231000
pounds) while
maintaining speed on curves, hills, and the like. in the illustrated
embodiment, three rail cars 90
are coupled to an engine 212, however, in other embodiments, more or few rails
cars 90 may be
coupled to the engine 212. Each rail car 90 is carrying four containers 10
along a curved. portion
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214 of the rail section 210. As shown by the arrow 216, a force is acting on
the rail cars 90 along
the curve, thereby driving the rail cars 90 radially outward away from a
center 218. By
balancing the containers 10 along the length 108 of the mil car 90, the effect
of the force 216
may be reduced, thereby enabling the engine 212 to travel along the curved
portion 214 without
significant adjustments to speed. For example, the engine 212 can keep
traveling in a direction
of travel 220, represented by the arrow without adjusting for speed while
still maintaining the
large load supported by the rail cars 90. Moreover, as described above,
because in the illustrated
embodiment four containers 10 are positioned on the rail cars 90, the overall
length of the system
may be reduced. For example, if the rail car 90 were only capable of
supporting two containers
10, the length of the system would effectively double. Accordingly, different
considerations
(e.g., bridge length, weight limits, rail yard space, etc.) would come under
scrutiny to determine
whether the containers 10 could be Shipped economically via rail However,
because the rail
cars 90 are capable of supporting the weight of the containers 10,
transportation of the containers
may be accomplished without special considerations for weight, height, length,
or other
factors.
[00661 As described above, the rail cars 90 can be utilized to support and
transport the containers
10 along railways. HG. 13 is a schematic perspective view of an embodiment of
a proppant
delivery system 230. The system 230 includes a track 232 formed in the nature
of a circuit. A
container-hauling trolley 234 is movably positioned on the track 232 and
configured to travel
along the circuit to position the containers 10 to receive proppant. For
example, in the illustrated
embodiment, a proppant supply station 236 is positioned on the track 232. As
shown, the circuit
continues below the proppant supply station 236, positioned adjacent the track
232, to enable the
trolley 234 to Move one or more containers into position to receive proppant
from one or more
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silos 238. For example, the trolley 234 may transition the containers" 0 into
a loading bay 240 to
receive the proppant (e.g., from an opening in the bottom of the silos 238).
As the circuit
continues, one or more cranes 242 (e.g., a gantry crane) may be utilized to
remove the filled
containers 10 from the trolley 234 and to stage the containers 10 adjacent to
the rail section 210
having the rail cars 90 or a roadway having trucks 244 for transporting the
proppant. For
example, in certain embodiments, the crane 242 may load the containers 10
directly onto the rail
car 90 or the truck 244. In other embodiments, the crane 242 may stage (e.g.,
stack) the
containers 10 proximate the rail section 210 or the roadway for later loading
(e.g., via a forklift).
In certain embodiments, the silo 238, rail section 210, and/or the roadway are
positioned at the
mine where the proppant is gathered. As a result, the container 10 and the
rail cars 90 may be
utilized to transport the proppant directly from the mine, thereby improving
efficiencies and
reducing costs by reducing the number of handling steps the proppant goes
through before
reaching the well site.
100671 In embodiments, as the empty proppant containers 10 arrive back from
the field by either
rail car 90 or by truck 244, the rail cars 90 or trucks 244 are positioned on
the track or road that
runs underneath the cranes 242. The cranes 242 remove the empty containers 10
from the trucks
244 or rail cars 90 to the empty inventory stack. Once the empty containers 10
are removed from
the rail cars 90 or trucks 244, the cranes 242 will begin to reload the rail
cars 90 or trucks 242
from the inventory stack of full containers. The train or trucks will depart
from the proppant
mine once they are completely reloaded. The filling of the proppant containers
10 by the use of
the trolleys 234 can occur simultaneous to the above-described process. A
constant flow of
empty proppant containers 10 are guided into the loading bay that are filled
with proppant from
the silos 238. Once filled, the proppant containers 10 exit the loading bay,
and then travel around
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the trolley track 232 until they are positioned underneath the cranes 242.
These filled proppant
containers 10 are then removed from the trolley cars, placed onto the
inventoty stack of filled
containers 10, and then replaced by empty proppant containers 10 from the
inventory stack of
empty containers 10. The replacement empty containers 10 are sent to the
loading bay along the
track and the trolleys so as to repeat the process.
100681 FIG. 14 is a flow chart of an embodiment ea method 250 for loading and
transporting
material (e.g., proppant) from a mine to a well site. The container 10 is
loaded with material at
the mine (block 252). For example, as described above, the proppant may be
dried and conveyed
into silos 238 which are utilized for long term storage. The containers 10 may
be positioned
beneath the silos 238 to load the containers 10. The containers 10 are then
positioned on the rail
cars 90 (block 254), The rail cars 90 may be specially designed to accommodate
the weight of'
the containers 10. For example, in the illustrated embodiments, the rail cars
90 include a
reinforced spine member 106 and bolsters 110 designed to receive and support
the containers 10.
Moreover, the rail cars 90 include the locking assemblies 120 to secure the
containers 10 to the
rail car 90.
100691 Thereafter, the containers 10 are transported to a staging area (block
256). For example,
the staging area may be located near the well site (e.g., within driving
distance). The containers
are then unloaded at the staging area (block 258). For example, the containers
10 may be
arranged in a stacked orientation to reduce the foot print of the containers
10 at the staging area.
Then, the containers 10 may be loaded onto the trucks 244 (block 260). The
trucks 244 transport
the containers 10 to the well site (block 262) for subsequent unloading (block
264). At the well
site, the containers 10 may be arranged in a stacked orientation to reduce the
foot print of the
containers 10 at the well site. Then, the containers 10 may be discharged such
that the proppant
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can be mixed and injected into a well (block 266). Accordingly, the method 250
illustrates how
the proppant can be loaded a single time, at the mine, and then the storage
container 10 is moved
from the rail car 90, to the staging area, to the truck 244, and then directly
to the well site with
minimal handling steps. As a resuh, the cost of transporting the proppant from
the mine to the
well site is reduced. Moreover, the likelihood of contamination of the
proppant is also reduced
because the proppant remains within the sealed container 10 for the duration
of the trip, until the
proppant is discharged from the container 10.
[00701 As described in detail above embodiments of the present disclosure are
directed toward
the rail car 90 having one or more bolsters 110 arranged along the length 108
over the spine
member 106. The spine member 106 includes a variable height (e.g., elevation)
along the. length
108 such that the first spine member height 132 at the first end 134 of the
rail car 90 is less than.
the second spine member height 136 at the midpoint 130. Moreover, the third
spine member
height 138 at the second end 140 is less than the second spine member height
136. As a result,
the spine member 106 has a greater cross-sectional area at the midpoint 130,
which is subject to a
greater force due to the load placed on the rail car 90_ Accordingly, the
weight of the rail. car 90
is reduced by utilizing less material at the first and second ends 134, 140.
As described above,
the bolsters 110 include the mounting platform 118 to receive and support the
containers 10.
The mounting platforms 118 extend vertically above the top surface of the 202
of the bolster 110
and elevate the containers 10 above the spine member 106. Further, the
mounting platforms 118
include the locking assemblies 120 to secure the containers 10 to the rail
cars 90. Accordingly,
the rail car 90 may receive several containers 10 in a side-by-side
arrangement to enable
economical ixansportation of containers 10 filled with proppant material from
a mine to a well
site.
28
[0071] The foregoing disclosure and description of the invention is
illustrative and explanatory
of the embodiments of the invention. Various changes in the details of the
illustrated
embodiments can be made within the scope of the appended claims without
departing from the
true spirit of the invention. The embodiments of the present invention should
only be limited by
the following claims and their legal equivalents.
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