How to Design and Build an Efficient Transload Facility? Fabian Ros & Joey A. Chbeir

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1 How to Design and Build an Efficient Transload Facility? Fabian Ros & Joey A. Chbeir

2 Proppant Handling and Storage System Allows to Transfer Proppants Mainly Between Rail Cars and Pump Trucks In a safe, economical, efficient and controlled manner.

3 Consumption of Sand In Hydraulic Fracking 20 Total Consumption of 15 Sand & Gavel

4 Source: ant sand export.html Source: bulk_transfer.html

5 Mineralogical Analysis (Si O4%) Si (US Mesh) Size M h) Sphericity & Roundness Silt Test (Turbidity) Crush Resistance Test (KSI) Maximum Acid Solubility Picture source: 1.com/news/articl e/ /391/gr oup appeals Minn frac sand permit

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7 A minimum of 90 % of the tested sand sample should fall between the designating sieve sizes; i.e., 16/30, 20/40, 30/50, etc. Not over 0.1 % of the total tested sand sample should be larger than the first sieve and not over 1.0 % should be smaller than the last sieve size. RECOGNIZED FRAC SAND SIZES Frac Sand Size Designation Mesh Mesh Mesh Mesh Mesh Mesh Mesh Mesh 6/12 8/16 12/20 16/30 20/40 30/50 40/70 70/140 Nest of U.S.A Sieves. Recommende d for Testing Pan Pan Pan Pan Pan Pan Pan Pan

8 U.S. MESH MICRONS INCHES

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10 Volume Speed Accuracy Efficiency Reliability Flexibility Proximity Quality Safety Cost Control

11 Small Footprint With ability bl to handle large truck volume Accurate Systems Monitoring Inventory Material Handling Bill of Lading Ability to Store Different Products Ability to Operate 24/7 Effective Dust Control System

12 Inadequate Storage Areas Product Degradation & Segregation Product Contamination/Cross Contamination Long Chutes Rotating Distributors Screw Conveyors Incompatible systems (i.e., not designed to handle sand) Exposing employees to respirable dust

13 When talking about respirable dust, we are referring to particles that are small enough to penetrate the nose and upper respiratory system and deep into the l lungs. [Th ] are [They] generally beyond the body s natural clearance mechanisms of cilia and mucous and are more likely to be retained. Dust Control Handbook for Minerals Processing, Processing OSHA. Image Source:

14 Image Source: Regulating agencies have defined respirable dust as any particle that is smaller than 10-microns

15 U.S. MESH MICRONS INCHES

16 Typical atmospheric dust to 30 microns Pollens microns Mold spores microns Fertilizer is microns Threshold of naked-eyeeye visibility is about 40 microns Pollen is about 60 microns Diameter of a typical human hair is about 70 microns ( microns) Size of table salt is about 100 microns Beach sand varies from 100 to 2000 microns Eye of a needle is about 1230 microns

17 Silicosis as an occupational problem for centuries Hawks Nest Tunnel Disaster of 1936 Silicosis prevention regulations Lawsuits in early 21stCentury OSHA s concern about silica in the HF industry OSHA s current attempt to lower PELs Silica dust: NOT in the well and NOT in the lungs

18 Caused by breathing very fine silica dust Invisible silica dust enter the person s lungs, producing inflammation and scarring of the lung tissue Three (3) types of silicosis: Chronic: More than ten (10) years of exposure to small amounts of silica dust Accelerated: Five (5) to ten (10)years of exposure to moderate amounts of silica dust. Acute: few weeks to five (5) year of exposure to large amounts of silica dust

19 Health Risks To: Workers and neighbors Once in the lungs, it cannot be expelled Silicosis, asbestosis, pneumonia, tuberculosis, and/or pulmonary edema Safety Risks Poor visibility Unpleasant working environment Explosion Risks When the following are combined: Fuel Ignition Source Oxidizer Suspension of dust into a cloud Confinement of the dust cloud

20 You should not be concerned about you see. The risk is from what you can t see risk is from what you can t see.

21 Site Selection Rail Service Availability (Unit Train or Manifest) Highway access Proppants Demand Proppants type No of wells to be serviced

22 Material Physical Characteristics Density Flowability y Surge Charge Angle Angle of Repose Abrasiveness Flow Rate Tons Per Hour Material Handling Equipment Selection Belt Conveyors Vibratory Equipment Bucket Elevators Augers or Screw Conveyors P Pneumatic ti C Conveyors Gravity Chutes Distributor Dust Collection System

23 Density = lbs/ cu.ft Flowabiity = Good Surcharge angle = 20 deg Angle of Repose= 42 deg Abrasiveness = High Flow Rate= 250 TPH

24 Material Handling Equipment Selection Belt Conveyors = Adequate Vibratory y Equipment= q p Not Adequate q Bucket Elevators= Adequate Augers or Screw Conveyors= Not Adequate Pneumatic Conveyors= Not Adequate Gravity Chutes= Limited length Distributor= Not Adequate

25 Material Handling Equipment Selection Belt Conveyors = Adequate Vibratory y Equipment= q p Adequate q Bucket Elevators= Adequate Augers or Screw Conveyors= Adequate Pneumatic Conveyors= Not Adequate Gravity Chutes= Limited Length Distributor= Limited Destinations

26 Source: Mechanical Conveyors Selection and Operation, p. 198

27 MATERIAL WEIGHT LBS. PER CU. FT. CODE Sand Dry Bank (Damp) B47 Sand Dry Bank (Dry) B37 Sand Dry Silica B27 Sand Foundry (Shake Out) D37 Sand (Resin Coated) Silica 104 B27 Sandstone, broken D37

28 Engineering Practices to Control Dust Exposure: Shortening drops between conveyors Loading material in the same direction as the receiving belt is moving Avoiding drastic changes in the material trajectory t Maintaining a cohesive material stream while controlling the flow of air into and out of the transfer point Limit the air intake areas in transfer points

29 Is Moisture Acceptable? NO Dust Collection YES Air Flow > 900 ft 3 /min NO Active Dust Collection Passive Dust Collection

30 Y i l d 4 l tt f th Al h b t C D E & F You simply need 4 letters of the Alphabet: C, D, E, & F Exhaust hood to capture dust at the source Ductwork to transport captured air and dust to a collector Collector to separate dust from air Fan and motor for exhaust volume and energy

31 The following factors should be considered: Dust concentration Characteristics ti of the air stream Characteristics of dust Method of disposal Separation Techniques: Cyclones Wet Scrubbers Electrostatic Precipitators Cartridge Filter Collectors Bag House System Types (Central or Local) Size & Air to Cloth Ratio

32 Reducing Dust at Transfer Points Effective e Designs & Production ctiontechniqueses Larger Settling Zones Airflow < 200 ft /min Using Modular Chutewall Systems Engineered Flow Chutes Controlling Air Entering the Transfer Point Dust Curtains at the Exit Area Installation of Dust Bags

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34 Source: techbuildings.com/index.cfm?nodeid=24752

35 Source: silos.com/steel Silo for Sale/Flat Bottom Silos.html

36 Source:

37 Source: NIOSH Source:

38 Source:

39 Source:

40 Source:

41 Source:

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