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

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

50 45 40 35 30 25 Consumption of Sand In Hydraulic Fracking 20 Total Consumption of 15 Sand & Gavel 10 5 0 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

Source: http://flexfracsand.com/propp ant sand export.html Source: http://www.sandersvillerailroad.com/ bulk_transfer.html

Mineralogical Analysis (Si O4%) Si (US Mesh) Size M h) Sphericity & Roundness Silt Test (Turbidity) Crush Resistance Test (KSI) Maximum Acid Solubility Picture source: http://www.kare1 1.com/news/articl e/1004507/391/gr oup appeals Minn frac sand permit

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. 4 6 8 12 16 20 30 50 Sieves. Recommende 6 8 12 16 20 30 40 70 d for Testing. 8 12 16 20 30 40 50 100 10 14 18 25 35 45 60 120 12 16 20 30 40 50 70 140 16 20 30 40 50 70 100 200 Pan Pan Pan Pan Pan Pan Pan Pan

U.S. MESH MICRONS INCHES 6 3360 0.1320 8 2380 0.0937 12 1680 0.0661 16 1190 0.0469 20 841 0.0331 40 420 0.0165 50 297 0.0117 60 250 0.0098 70 210 0.0083 140 105 0.0040 200 74 0.0029 325 44 0.00170017 400 37 0.0015 550 25 0.00099 625 20 0.0007900079 1250 10 0.000394 1750 8 0.000315

Volume Speed Accuracy Efficiency Reliability Flexibility Proximity Quality Safety Cost Control

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

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

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: http://www.eurosil.eu

Image Source: http://www.eurosil.eu Regulating agencies have defined respirable dust as any particle that is smaller than 10-microns

Typical atmospheric dust 0.001 to 30 microns Pollens 10-1000 microns Mold spores 10 30 microns Fertilizer is 10 1000 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 (40-300 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

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

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

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

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.

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

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

Density = 90 100 lbs/ cu.ft Flowabiity = Good Surcharge angle = 20 deg Angle of Repose= 42 deg Abrasiveness = High Flow Rate= 250 TPH

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

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

Source: Mechanical Conveyors Selection and Operation, p. 198

MATERIAL WEIGHT LBS. PER CU. FT. CODE Sand Dry Bank (Damp) 110 130 B47 Sand Dry Bank (Dry) 90 110 B37 Sand Dry Silica 90 100 B27 Sand Foundry (Shake Out) 90 100 D37 Sand (Resin Coated) Silica 104 B27 Sandstone, broken 85 90 D37

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

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

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

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

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

Source: http://www.youtube.com/watch?v=auqexqpu3v4

Source: NIOSH Source: http://www.youtube.com/watch?v=auqexqpu3v4

Source: http://www.youtube.com/watch?v=auqexqpu3v4