Proppant discharge system and a container for use in such a proppant discharge system

• US 9,694,970 B2
• Filed: 05/02/2016
• Issued: 07/04/2017
• Est. Priority Date: 07/23/2012
• Status: Active Grant

• Current Assignee: SandBox Enterprises LLC (U.S. Silica Holdings, Inc.)
• Original Assignee: Oren Technologies LLC (U.S. Silica Holdings, Inc.)
• Inventors: Oren, John, Oren, Joshua
• Primary Examiner(s): SNELTING, JONATHAN D
• Application Number:
  US15/144,296
• Publication Number:
  US 20160244253A1
• Time in Patent Office: 428 Days
• Field of Search: 410 68, 414328, 414329, 414332, 414810
• CPC Class Codes: B60P 1/56 the load-transporting element having bottom discharging openings
• CPC Class Codes: B65D 2231/008 integral with the container wall
• CPC Class Codes: B65D 2547/04 Closures with discharging devices other than pumps
• CPC Class Codes: B65D 2588/12 specially adapted for transport
• CPC Class Codes: B65D 2590/664 actuating mechanism other than manual, e.g. pneumatic, electropneumatic, hydraulic, electromagnetic
• CPC Class Codes: B65D 7/00 Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, components made wholly or mainly of metal specially constructed to be opened by cutting, piercing, or tearing of wall portions B65D17/00; pallets B65D19/00; tanks for domestic water storage heaters F24H1/181
• CPC Class Codes: B65D 83/06 for dispensing powdered or granular material B65D83/04 takes precedence
• CPC Class Codes: B65D 88/02 rigid B65D88/34 - B65D88/78 take precedence; hoppers B65D88/26; special vessels for collecting or storing rain-water for use in the household E03B3/03; cesspools E03F11/00
• CPC Class Codes: B65D 88/022 in multiple arrangement, e.g. stackable, nestable, connected or joined together side-by-side
• CPC Class Codes: B65D 88/12 specially adapted for transport associated with vehicles, see the relevant subclasses of B60 - B64
• CPC Class Codes: B65D 88/121 ISO containers
• CPC Class Codes: B65D 88/129 Transporter frames for containers
• CPC Class Codes: B65D 88/26 Hoppers, i.e. containers having funnel-shaped discharge sections B65D88/34 - B65D88/78 take precedence
• CPC Class Codes: B65D 88/28 Construction or shape of discharge section
• 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 88/38 with surface water receiver, e.g. drain
• 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 88/542 Ramps forming part of the container ramps per se B65G69/28; for ambulances A61G3/061; for vehicles in general B60P1/43
• 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: B65D 90/58 : having closure members sliding in the plane of the opening
• CPC Class Codes: B65D 90/587 : having a linear motion
• CPC Class Codes: B65D 90/66 : Operating devices therefor
• CPC Class Codes: B65G 2201/042 : Granular material
• CPC Class Codes: B65G 2814/0319 : through a closable or non-closable outlet opening
• CPC Class Codes: B65G 2814/032 : using a belt or chain conveyor in or beneath the opening
• CPC Class Codes: B65G 65/30 : Methods or devices for filling or emptying bunkers, hoppers, tanks, or like containers, of interest apart from their use in particular chemical or physical processes or their application in particular machines, e.g. not covered by a single other subclass devices for tilting and emptying containers B65G65/23; such containers having means facilitating filling or emptying B65D88/54
• CPC Class Codes: B65G 65/40 : Devices for emptying otherwise than from the top
• CPC Class Codes: B65G 65/42 : using belt or chain conveyors

Abstract

A proppant discharge system has a container with an outlet positioned in a bottom thereof and a gate affixed adjacent the outlet so as to be movable between a first position covering the outlet to a second position opening the outlet, and a support structure having an actuator thereon. The container is removably positioned on the top surface of the support structure. The actuator is engageable with gate so as to move the gate from the first position to the second position. A conveyor underlies the container so as to receive proppant as discharged from the container through the outlet. The container can be a ten foot ISO container.

Claims

1. A method of providing fracking proppant to a well site for use when hydraulic fracking is to be performed, the method comprising:

removing, by use of a forklift positioned at the well site, a series of a plurality of individual containers that each contains fracking proppant and are each positioned on a respective trailer of a respective transport road vehicle, upon arrival to and when positioned adjacent a well site at a location where hydraulic fracking is to be performed, each of the separate trailers having a single one of the plurality of containers positioned thereon, each of the plurality of containers having an outlet positioned at a bottom thereof, a pair of end walls, a pair of side walls, a plurality of ramps extending downwardly and inwardly from a plurality of the walls toward the outlet, one or more support braces positioned at an elevation above the ramps and between frame members of the container to structurally support the container when fracking proppant is positioned therein, a gate positioned to prevent proppant from flowing from the outlet when in a closed position and to allow proppant to flow from the outlet when in an open position, and one or more fork receptacles positioned adjacent the bottom of the container to receive forks from the forklift therein thereby to lift the container;

transferring, after removal from each separate trailer of the road vehicle, each of the plurality of containers with the forklift to a support structure positioned at the well site, the support structure having a frame with top portions thereof extending substantially in a horizontal plane, the horizontally extending top portions of the frame of the support structure including a plurality of cradles each positioned to receive one of the plurality of containers so that each of the plurality of containers is positioned in a side-by-side relationship along the top portions of the support structure;

actuating the gate of each of the plurality of containers, by use of an actuator connected to the support structure, to move the gate from the closed position to the open position; and

discharging, responsive to actuation of the gate of each of the plurality of containers, by gravity feed the fracking proppant contained within each of the plurality of containers after a respective one of the plurality of containers is positioned on the support structure and within a cradle of the plurality of cradles, the proppant within each of the plurality of containers flowing along the plurality of ramps and through the outlet positioned at the bottom of each container.

2. The method as defined in claim 1, wherein each of the plurality of containers includes a plurality of structural support members positioned at corner junctions between the side walls and the end walls, the plurality of structural support members being operably fixed to the frame.

3. The method as defined in claim 2, wherein the support structure further comprises:

at least one hopper positioned below the plurality of cradles to receive the fracking proppant from the container and to direct the fracking proppant therefrom.

4. The method as defined in claim 2, wherein the plurality of structural support members each include a top header and a bottom footer, the top header extending vertically higher than a top of each of the plurality of containers and the bottom header extending vertically lower than the bottom of each of the plurality of containers, the method further comprising:

positioning a first container adjacent the well site; and

stacking a second container on top of the first container such that the bottom headers of the second container are in contact with the top headers of the first container.

5. The method as defined in claim 1, further comprising:

directing the fracking proppant to a desired location with a chute, the chute receiving the fracking proppant downstream from proppant discharging from the container.

6. The method as defined in claim 1, further comprising:

controlling the flow of fracking proppant with one or more flow gates positioned adjacent the container when positioned on the support structure, the one or more flow gates configured to move between closed and open positions.

7. The method as defined in claim 6, further comprising:

controlling the one or more flow gates with one or more actuators attached to the one or more flow gates and configured to move the one or more flow gates in increments between the closed and open positions.

8. The method as defined in claim 1, wherein moving the container from the trailer includes lifting the container with the forklift and setting the container on top of the support structure, the method further comprising:

transporting the support structure from one location within the well site to another location within the well site on wheels attached to the support structure, and delivering the fracking proppant to a blender.

9. The method as defined in claim 1, wherein the container has an open area adjacent a bottom of the container to allow for visual access into a portion of the container.

10. A method for storing and unloading of fracking proppant at a well site for use when hydraulic fracking is to be performed, the method comprising:

removing a plurality of containers that contain fracking proppant therein from a trailer of one or more transport vehicles adjacent to a well site, each of the plurality of containers having an outlet positioned at a bottom thereof, a pair of end walls, a pair of side walls, a plurality of structural support members extending between the bottom and a top, and a ramped section proximate the bottom, and one or more support braces positioned at an elevation above a vertical extent of the ramped section to structurally support the container when fracking proppant is positioned therein;

arranging a first container of the plurality of containers in a stacked orientation with a second container of the plurality of containers such that the respective structural support members of the first and second containers are aligned and in contact with one another while the first and second containers are stacked in the stacked orientation;

transferring the first container onto a support structure from the stacked orientation, the first container being positioned on top of the second container before being moved to the support structure and the first container being removed from the stacked orientation via a forklift; and

selectively opening the outlet of the first container to direct the fracking proppant out of the container and to a location positioned below the support structure, to deliver the fracking proppant away from the first container.

11. The method as defined in claim 10, further comprising:

delivering the fracking proppant away from the first container toward a desired location at the well site where hydraulic fracking is to be performed so that the fracking proppant is introduced to fracking fluid for passage into a wellbore at the well site.

12. The method as defined in claim 10, wherein the plurality of structural support members are operably fixed to a frame, the frame extending about an exterior of the end walls and the side walls, the method further comprising:

directing the fracking proppant to a desired location with a chute configured to receive fracking proppant.

13. The method as defined in claim 10, further comprising:

controlling the flow of fracking proppant from the container with a flow gate positioned adjacent the container, the flow gate configured to move between closed and open positions.

14. The method as defined in claim 13, further comprising:

controlling the flow gate with one or more actuators attached to the flow gate and configured to move the flow gate in increments between the closed and open positions.

15. The method as defined in claim 10, wherein the support structure further comprises:

a plurality of hoppers each positioned to receive fracking proppant from one of the plurality of containers and direct the fracking proppant therefrom, each hopper corresponding to one of a plurality of cradles and having an inverted V-shaped gate positioned to interrupt the flow of fracking proppant when the fracking proppant passes from the one of the plurality of containers.

16. A method for storing and unloading of fracking proppant at a well site for use when hydraulic fracking is to be performed, the method comprising:

loading a plurality of containers filled with fracking proppant onto a trailer of at least one transport vehicle, each container of the plurality of containers having a pair of end walls, a pair of side walls, a top, a bottom having an outlet, a plurality of structural support members positioned at intersections between the pair of end walls and the pair of side walls, and one or more support braces positioned at an elevation above a vertical extent of a lower ramped section of the container to structurally support the container when fracking proppant is positioned therein;

transporting the plurality of containers via the at least one transport vehicle to a well site adjacent an area where hydraulic fracturing is to be performed;

removing the plurality of containers from the trailer of the at least one transport vehicle when the at least one transport vehicle is proximate the well site, the well site having a staging area to store the plurality of containers until hydraulic fracturing is to be performed;

arranging the plurality of containers in a stacked configuration in the staging area such that one or more containers of the plurality of containers are stacked on top of one another and the plurality of structural support members of each of the one or more containers are substantially aligned;

removing a container of the plurality of containers from the stacked configuration and positioning the container onto a support structure;

the support structure being positioned proximate the well site and arranged to receive the plurality of containers in a side by side arrangement; and

dispensing the fracking proppant from the container such that the fracking proppant flows out of the outlet via gravity feed and to a location positioned beneath the support structure.

17. The method as defined in claim 16, further comprising:

controlling the flow of fracking proppant from the container with a flow gate positioned adjacent the container, the flow gate configured to move between closed and open positions.

18. The method as defined in claim 17, further comprising:

controlling the flow gate with one or more actuators attached to the flow gate and configured to move the flow gate in increments between the closed and open positions.

19. The method as defined in claim 16, wherein the support structure further comprises:

a plurality of hoppers each positioned to receive fracking proppant from one of the plurality of containers and direct the fracking proppant therefrom.

20. The method as defined in claim 16, wherein movement of the plurality of containers from the trailer of the one or more transport vehicles and to the support structure from the stacked configuration is done via a forklift.