Systems and methods for bulk material storage and/or transport

• US 10,562,702 B2
• Filed: 07/26/2016
• Issued: 02/18/2020
• 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:
  US15/219,640
• Publication Number:
  US 20160332809A1
• Time in Patent Office: 1,302 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 bulk material storage container unit comprising:

a storage component that includes a generally rectangular portion and a tapered portion, the generally rectangular portion having a plurality of side walls and the tapered portion having a plurality of tapered walls extending from each side wall of the plurality of side walls in a narrowing manner toward an opening to direct bulk material stored within an interior volume of the storage component toward the opening, the bulk material being proppant used for hydraulic fracturing;

a top surface attached to said storage component, said top surface including one or more openings and a lid member corresponding to and positioned to overlie the one or more openings when in a closed position;

a frame component attached to said storage component, said frame component including a plurality of storage component support members to provide support to the storage component while the storage component is filled with bulk material, and a plurality of vertical storage component support members attached to corners of the storage component and extending from a top end at the top surface to a bottom end below the opening in the storage component;

one or more transfer components positioned proximate the opening to facilitate movement of the bulk material storage container unit;

one or more vertical 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

a dispenser component attached to said storage component and being moveable between an open position and a closed position to regulate the flow of proppant from the storage component, the dispenser component positioned proximate a bottom of the frame component.

2. The bulk material storage container unit of claim 1, further comprising:

a diverter component attached to the storage component, said diverter component reducing the angle of repose of particulates entering the storage component through the one or more openings of the top surface.

3. The bulk material storage container unit of claim 1, further comprising a length of about 12 feet or less, a width of less than about 8 feet 6 inches, and a height of less than about 10 feet and wherein the storage component has a capacity of up to 675 cubic feet of volume.

4. The bulk material storage container unit of claim 3, wherein said length is about 12 feet said width is about 8 feet 4 inches, and said height is about 9 feet 9 1/16 inches.

5. The bulk material storage container unit of claim 1, wherein said plurality of storage component support members comprise one or more of:

a plurality of vertical storage component support members, a plurality of horizontal storage component support members, and a plurality of angled storage component support members.

6. The bulk material storage container unit of claim 1, wherein the one or more transfer components are arranged on the frame component, the one or more transfer components being positioned to accommodate forks from a forklift to enable movement of the bulk material storage container unit.

7. The bulk material storage container unit of claim 1, wherein each tapered wall of the plurality of tapered walls are disposed at an angle with respect to a horizontal surface said angle being in the range between about 25 degrees and 60 degrees.

8. The bulk material storage container unit 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 and the second height being different.

9. The bulk material storage container unit of claim 1, wherein the frame component is arranged about the storage component such that an open area is formed adjacent the tapered walls to enable visual access of an outer surface of the tapered walls through the open area.

10. The bulk material storage container unit of claim 1, wherein the plurality of storage component support members comprises a plurality of vertical storage component support members extending from the top surface to a bottom, the plurality of vertical storage component support members arranged to receive and support a second bulk material storage container unit stacked on top of the bulk material storage container unit, the plurality of vertical storage component support members of the second bulk material storage container unit attaching to the plurality of vertical storage component support members of the bulk material storage container unit.

11. The bulk material storage container unit of claim 1, wherein the plurality of storage component support members further comprises a plurality of angled storage component support members positioned in contact with the storage component to provide additional support to the bulk material storage container unit.

17. The bulk material storage container unit of claim 5, wherein the one or more vertical support members extend vertically from the one or more transfer components to one or more of the plurality of angled storage component support members.

12. A bulk material storage container unit comprising:

a storage component that includes a generally rectangular portion and a tapered portion, the generally rectangular portion having a plurality of side walls and the tapered portion having a plurality of tapered walls extending from each side wall of the plurality of side walls in a narrowing manner toward an opening to direct bulk material stored within an interior volume of the storage component toward the opening, the bulk material being proppant used for hydraulic fracturing, the plurality of side walls including two pairs of side walls, a first pair of side walls having a first height and the second pair of side walls having a second height, the first height and the second height being different, each tapered wall of the plurality of tapered walls being disposed at an angle with respect to a horizontal surface, the being in the range between 25 degrees and 60 degrees;

a top surface attached to said storage component, said top surface including one or more openings and a lid member corresponding to and positioned to overlie the one or more openings when in a closed position;

a frame component attached to said storage component, said frame component including a plurality of storage component support members to provide support to the storage component while the storage component is filled with bulk material, the frame component being arranged about the storage component such that an open area is formed adjacent the tapered walls to enable visual access of an outer surface of the tapered walls through the open area, wherein the plurality of storage support members includes a plurality of vertical storage component support members attached to corners of the storage component and extending from a top end at the top surface to a bottom end below the opening in storage component;

one or more transfer components positioned proximate the opening to facilitate movement of the bulk material storage container unit;

one or more vertical 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

a dispenser component attached to said storage component and being moveable between an open position and a closed position to regulate the flow of proppant from the storage component, the dispenser component positioned proximate a bottom of the frame component.

13. The bulk material storage container unit of claim 12, wherein said plurality of storage component support members comprise one or more of:

a plurality of vertical storage component support members, a plurality of horizontal storage component support members, and a plurality of angled storage component support members.

14. The bulk material storage container unit of claim 13, wherein the one or more transfer components are arranged on the frame component, the one or more transfer components being positioned to accommodate forks from a forklift to enable movement of the bulk material storage container unit.

15. The bulk material storage container unit of claim 12, wherein the plurality of storage component support members comprises a plurality of vertical storage component support members extending from the top surface to a bottom, the plurality of vertical storage component support members arranged to receive and support a second bulk material storage container unit stacked on top of the bulk material storage container unit, the plurality of vertical storage component support members of the second bulk material storage container unit attaching to the plurality of vertical storage component support members of the bulk material storage container unit.

16. The bulk material storage container unit of claim 15, wherein the plurality of storage component support members further comprises a plurality of angled storage component support members positioned in contact with the storage component to provide additional support to the bulk material storage container unit.

18. The bulk material storage container unit of claim 13, wherein the one or more vertical support members extend vertically from the one or more transfer components to one or more of the plurality of angled storage component support members.