Systems and methods for bulk material storage and/or transport

• US 10,538,381 B2
• Filed: 09/24/2012
• Issued: 01/21/2020
• Est. Priority Date: 09/23/2011
• Status: Active Grant

• Current Assignee: SandBox Enterprises LLC (U.S. Silica Holdings, Inc.)
• Original Assignee: SandBox Logistics LLC (U.S. Silica Holdings, Inc.)
• Inventors: Harris, Robert A.
• Primary Examiner(s): Kelly, Timothy P.
• Application Number:
  US13/625,675
• Publication Number:
  US 20140083554A1
• Time in Patent Office: 2,675 Days
• Field of Search: 141286, 141231, 414328, 52197, 222166, 206598, 239504
• CPC Class Codes: B65B 1/06 by gravity flow
• CPC Class Codes: B65D 88/30 specially adapted to facilitate transportation from one utilisation site to another collapsible hoppers B65D88/52
• CPC Class Codes: B65D 88/32 in multiple arrangement
• CPC Class Codes: B65D 88/54 characterised by means facilitating filling or emptying filling or emptying features for flexible large containers B65B69/0075; construction or shape of discharge section of hoppers B65D88/28; gates or closures B65D90/54; filling or emptying bunkers, hoppers, or like containers B65G65/30
• CPC Class Codes: B65D 90/0033 Lifting means forming part of the container B65D90/0006, B65D90/0026 take precedence; loading or unloading container on or from a truck B60P1/6418; lifting the container using a crane B66C1/663
• CPC Class Codes: B65D 90/20 Frames or nets, e.g. for flexible containers
• CPC Class Codes: B65D 90/54 Gates or closures for manholes B65D90/10; covers or similar closure members, for pressure vessels in general F16J13/00; valves per se F16K; doors for containers B65D90/008
• CPC Class Codes: B65G 2201/0235 Containers
• CPC Class Codes: B65G 57/02 by adding to the top of the stack
• CPC Class Codes: B65G 67/02 Loading or unloading land vehicles

Abstract

Bulk material storage units that can be placed on flatbeds that can be hauled in various manners, including rail cars or trucks, to the destination and removed from the flatbed for temporary storage at the destination, freeing the transportation mode, e.g., rail cars or trucks, to be used elsewhere. Embodiments of the bulk material storage unit of the present invention replace rail hopper cars or truck trailers to hold the bulk material during transportation as well as provide temporary storage at the desired location, e.g., the origin or destination, without tying up transportation resources.

Claims

1. A container to receive and store proppant used for hydraulic fracturing, the container comprising:

a plurality of side walls forming a generally rectangular portion with four corners;

a plurality of tapered walls extending downwardly and inwardly from each of the plurality of side walls, the plurality of tapered walls forming a tapered portion that, together with the generally rectangular portion, form an interior volume to store the proppant;

a top surface attached to the generally rectangular portion, the top surface having an upper opening for directing the proppant into the interior volume;

a lid member substantially covering and protecting the upper opening;

a lower outlet arranged at a bottom of the interior volume, the lower outlet formed by a distal end of each of the plurality of tapered walls, the lower outlet positioned to direct the proppant out of the interior volume as the proppant flows along the plurality of tapered walls;

a dispensing component connected to and substantially covering the lower outlet for retaining proppant stored in the container when positioned in a closed position, the dispensing component further being positioned to rotatably move to one of a plurality of open positions, each of the plurality of open positions comprising a degree of openness between the closed position and a fully open position, in order to regulate a rate of flow of the proppant from the lower outlet,

the dispensing component, in combination with the top surface, the lid member, the plurality of side walls, and the plurality of tapered walls, generally sealing the container when in the closed position to thereby isolate the proppant when stored within the interior volume from the surrounding environment; and

a frame component providing support for the container, the frame component including vertical support members attached to the plurality of side walls, each vertical support member being attached to the generally rectangular portion to form a corner thereof and extending from a top end at the top surface to a bottom end below the lower outlet, and one or more transfer components positioned proximate the lower outlet to facilitate movement of the container.

2. The container of claim 1, wherein the plurality of side walls comprises two pairs of side walls, a first pair of side walls having a first height, and a second pair of side walls having a second height, the first height being different than the second height.

3. The container of claim 1, wherein the frame component comprises horizontal support members and angled support members coupled to the vertical support members, the frame component arranged to form an open area proximate respective outer surfaces of the plurality of tapered walls to enable visual inspection of the respective outer surface through gaps formed between the vertical support members, horizontal support members, and angled support members.

4. The container of claim 3, further comprising one or more vertical storage component support members positioned to underlie the plurality of tapered walls and extend vertically from the one or more transfer components to a vertical extent below a bottom elevation of the rectangular portion of the storage component, and the one or more vertical storage component support members being positioned to extend vertically from the one or more transfer components to one or more of the plurality of angled storage component support members.

5. The container of claim 1, wherein the dispensing component is positioned to rotate about a central axis in order to regulate the rate of flow of the proppant from the lower outlet.

6. The container of claim 1, wherein the frame component further comprises horizontal support members attached to and extending between the vertical support members below the generally rectangular portion.

7. The container of claim 6, wherein the horizontal support members are attached at the bottom ends of the vertical support members.

8. The container of claim 7, wherein the one or more transfer components extend across a pair of horizontal support members.

9. The container of claim 7, wherein the outlet lies in a plane defined by the horizontal support members.

10. A container to receive and store proppant used for hydraulic fracturing, the container comprising:

a plurality of side walls forming a generally rectangular portion;

a plurality of tapered walls extending downwardly and inwardly from each of the plurality of side walls, the plurality of tapered walls forming a tapered portion that, together with the generally rectangular portion, form a storage component having an interior volume for storing proppant;

a top surface attached to the generally rectangular portion, the top surface having an upper opening for directing proppant into the interior volume;

a lid member substantially covering and protecting the upper opening;

a lower outlet arranged at a bottom of the interior volume, the lower outlet formed by a distal end of each of the plurality of tapered walls, the lower outlet positioned to direct the proppant out of the interior volume as the proppant flows along the plurality of tapered walls;

a dispensing component connected to and substantially covering the lower outlet for retaining proppant stored in the container when positioned in a closed position, the dispensing component further being positioned to rotatably move to one of a plurality of open positions, each of the plurality of open positions comprising a degree of openness between the closed position and a fully open position, in order to regulate a rate of flow of the proppant from the lower outlet,

the dispensing component, in combination with the top surface, the lid member, the plurality of side walls, and the plurality of tapered walls, generally sealing the container when in the closed position to thereby isolate the proppant when stored within the interior volume from the surrounding environment; and

a frame component providing support for the container, the frame component including vertical support members attached to the plurality of side walls and extending from a top end at the top surface to a bottom end below the lower outlet, one or more angled support members coupled to the vertical support members, one or more transfer components positioned proximate the lower outlet to facilitate movement of the container, and one or more vertical storage component support members positioned to underlie the tapered portion and extend vertically from the one or more transfer components to a vertical extent below a bottom elevation of the rectangular portion of the storage component to the one or more angled storage component support members.