Patent Publication Number: US-9409184-B1

Title: Portable sand plant, systems and methods

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit and priority of Provisional Patent Application Ser. No. 62/064,564 filed Oct. 16, 2014, for PORTABLE HYDRAULIC FRACTURING SAND PLANT AND METHODS under 35 U.S.C. §119(e), incorporated herein by reference in its entirety for continuity of disclosure. 
    
    
     DESCRIPTION 
     Background of the Invention 
     1. Field of the Invention 
     The present invention relates to material processing plants, material processing systems and material processing methods, and particularly portable sand plants, systems and methods utilized for processing hydraulic fracturing material. 
     2. Background Information 
     Hydraulic fracturing utilizes special sand which is delivered with fracturing fluid during a hydrofracing operation. Obtaining and using the sand having desired properties is important to the success of the hydraulic fracturing process. Sand plants are used to separate the desired sand from unwanted materials. Typically a sand plant is a fixed-location facility where sand is transported to the facility for sorting and cleaning. The selected sand is stacked and/or transported to a location for use in the hydraulic fracturing process to extract gas and/oil from the ground. 
     There exists at least one portable sand plant designed by CEMCO for separating desired frac sand. While the CEMCO prior art portable sand plant may have useful features, there is room for improvement. 
     SUMMARY OF THE INVENTION 
     The inventors have created an efficient, portable material processing plant, systems and related methods. 
     All or nearly all major processing plants use a cone-shaped hydrosizer for fractionating sand. Yet all of such plants are stationary or non-portable. While a taller, more efficient hydrosizer is highly desired, it presents problems when attempting to transport, set-up, stabilize and operate (and makes overall construction of a processing facility difficult, expensive and time consuming). Traditional non-portable sand plants that use a hydrosizer and especially a cone-shaped hydrosizer require a long time for set-up and preparation. A major component of the set-up and construction of such plants includes having to weld various components together, which substantially increases the time and expense for set-up. Such construction is also conducted at an outdoors environment which typically causes additional delay and expense due to weather conditions. A typical sand processing plant also uses several material processing devices, and these devices are usually arranged in ways that occupy a relatively large or inefficient footprint or lack a uniform or in-line compact arrangement. 
     Heretofore there have been no systems which utilize a cone-shaped hydrosizer in a portable context, or utilize pre-assembly of a cone-shaped hydrosizer for tip-in-place construction of a material processing plant. Heretofore there also has been no utilization of the space on a chassis which space is vacated by action of a tip-up material processing device where an additional processing device is placed at the vacated location, the additional processing device supplying material to the first material processing device. Heretofore there also have been no systems which present a complete solution for processing frac sand where the key material processing components used in of the process are configured on a single chassis or configured with an in-line arrangement on a single chassis. The present invention makes these and other uses possible. 
     In accordance with an aspect of the invention, a hydrosizer is positioned on a portable chassis which chassis also includes key processing equipment for a sand processing operation. For instance, in addition to a cone-style hydrosizer, the chassis includes an initial wet screen, at least one attrition cell, and a dewatering screen all positioned on or positionable on the chassis. The chassis is portable and configured to be placed directly on the ground. An initial wet screen separates sand material to be sent to the attrition cell which scrubs or removes organics or clays and other unwanted materials from the sand particles before the sand is treated in the hydrosizer which further separates the sand. The sand exits the hydrosizer and is dewatered at a screen device also placed on the chassis. All of these components (wet screen, attrition cell, hydrosizer, and dewatering screen, together with related pumps and delivery devices) are arranged in-line on the chassis for an efficient processing operation and also for efficient assembly/construction of the processing plant. 
     In accordance with a further aspect of the invention, a chassis includes a tip-up hydrosizer and is configured such that additional sand processing components may be placed on the chassis for a processing operation. The chassis includes a wheel suspension and a goose-neck for transport of the sand plant on a roadway or other surface. In one aspect the chassis includes a base frame configured to rest upon the ground. 
     In a further aspect the invention includes a method of utilizing the portable sand plant including raising the chassis and removing a wheel suspension and then lowering the chassis such that the base frame rests upon the ground. Thereafter the hydrosizer is tipped-up into operational position and other processing equipment added to the chassis. 
     In a further aspect of the invention includes configuring the chassis such that the hydrosizer rests on a base frame during a transport mode where the base frame is positioned lower than a goose neck at a first end of the chassis and below a rear frame at a second end of the chassis. 
     A further aspect of the invention includes a portable material processing plant having a chassis configured to connect to a truck to transport the plant on a roadway, and a cone-style hydrosizer mounted to a tower structure rotatably connected to the chassis such that the hydrosizer is moveable from a horizontal orientation to a vertical orientation. 
     Additional aspects of the invention are provided herein. 
     The above partial summary of the present invention is not intended to describe each illustrated embodiment, aspect, or every implementation of the present invention. The figures and detailed description and claims that follow more particularly exemplify these and other embodiments and further aspects of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may be more completely understood in consideration of the following description of various embodiments of the invention in connection with the accompanying drawings, in which: 
         FIG. 1  is a perspective view of a portable material processing plant in accordance with one aspect of the present invention. 
         FIG. 2  is a side view of the processing plant of  FIG. 1 . 
         FIG. 3  is a perspective view of a further aspect of the invention. 
         FIG. 4  is a side view of the processing plant of  FIG. 3 . 
         FIG. 5  is a reverse perspective view of the processing plant of  FIG. 3 . 
         FIG. 6  is a cross-section view taken along line  6 - 6  of  FIG. 3 . 
         FIG. 7  is a perspective view of a feature for use in conjunction with the processing plant of the present invention. 
         FIG. 8  is a perspective view of a feature for use in conjunction with the processing plant of the present invention. 
         FIG. 9  is a top view of the material processing plant of  FIG. 1  with a component arranged in a horizontal position. 
         FIG. 10  is a top view of the material processing plant of  FIG. 1  with a component arranged in a vertical position. 
         FIG. 11  is a top view of a material processing plant in accordance with an aspect of the present invention. 
         FIG. 12  is a partial perspective view of component features in accordance with an aspect of the present invention. 
     
    
    
     While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not necessarily to limit the invention to the particular embodiments, aspects and features described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention and as defined by the appended claims. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIGS. 1-12 , various aspects of the invention are shown.  FIG. 1  is a perspective view showing one aspect of a portable material processing plant  20  having a chassis  22 . In one aspect plant  20  is a portable sand processing plant.  FIG. 2  shows a side view of plant  20 . Chassis  22  is a version of a “drop deck” trailer and includes a base frame  24  with a goose neck  26  positioned at a first end  22   a  of chassis  22  and a rear frame  28  positioned at a second end  22   b  of chassis  22 . Goose neck  26  is oriented generally horizontally and is positioned above base frame  24  which is also oriented generally horizontally. Rear frame  28  is also oriented generally horizontally and is positioned above base frame  24 . In one aspect base frame  24  is positioned lower than rear frame  28  and goose neck  24 . Rear frame  28  and goose neck  24  are elevated in relation to base frame  24 . It may be appreciated that goose neck  26  is configured such that a hitch of a tractor-trailer truck may be positioned underneath or in association with goose neck  26  for connection and transport. Rear frame  28  is configured such that a frame suspension  32  may be positioned underneath rear frame  28 . In one aspect frame suspension  32  includes wheels and is removeable. In one aspect chassis  22  is an approved over the road goose-neck or “drop-deck” type of trailer which is licensed, certified or otherwise authorized for legal transport down a roadway without the need to obtain special permits for transport. In one aspect chassis  22  is no greater than 73 feet in length and is less than 12 feet in width (or greater than 12 feet when considering the hydrosizer  30 ). Different lengths and widths may be used or established for chassis  22  without departing from the invention. 
     While  FIG. 1  and  FIG. 2  show aspects of the processing plant  20  in transport mode (or prior to assembly and operation),  FIG. 3  and  FIG. 4  show the plant  20  in one set-up mode option. General flow of material through plant  20  is described in the following non-limiting example: material such as dry sand and/or mixed sand and water (which may also include stones or other materials) is delivered (by conveyor or bucket or other delivery mechanism) to primary wet screen  50  where course materials are removed and where water is added to the remaining material to make a slurry which flows to sump  60 . Course materials may be removed, for instance, by use of a screen (such as where primary wet screen  50  includes a bottom deck equipped with a screen of 12 mesh variety, i.e., 12 openings per linear inch, or a sieve size of 1.7 mm, thus only allowing particles smaller than 1.7 mm to pass through the screen). Different mesh sized may be used as desired. In one aspect, different mesh may include, but not limited to 18 mesh which includes a sieve size of 1.0 mm. A pump  62  delivers the slurry to separator  70  which removes water and fine materials and allows the heavier damp material to drop into attrition cell or cells  72 . At cells  72  the material such as sand is treated by mixing and self-friction to remove small particles, clays, organics or other unwanted matter. The sand then drops to trough  74  and then into sump  44 . The overflow water and small particles from separator  70  also drop to trough  74  and recombine with the material treated in cells  72  and then to sump  44 . A slurry of water and material is positioned in sump  44 . A pump  64  delivers the slurry mixture to cyclone separator  40  where overflow is separated through conduit  41  and delivered to box  43  or other location. The overflow contains water and small materials which may be discarded or subsequently separated or treated. The material within separator  40  which does not go to the overflow will drop thorough separator  40  and into hydrosizer  30 . The treatment within hydrosizer  30  (and with the other mentioned components) is described in further detail below. Material drops down from hydrosizer  30  into a feed box  46  where it is delivered to a dewatering screen assembly  42 . Material such as sand is dewatered and proceeds down a discharge chute  49  for storage or transport. The material delivered to screen assembly  42  is often the most desired product produced from the plant  20  (such as sand used in hydraulic fracturing). The overflow material from separator  40  may also be desired material so that additional processing may be arranged for such overflow. Different or additional processing devices may be used in conjunction with plant  20  and chassis  22 . To assure a complete processing solution the four key components of a sand processing system under the present invention include 1) a primary or initial wet screen component for making an initial separation of the sand to pass the desired sand to 2) an attrition cell or tub wherein the sand is scrubbed for subsequent delivery to a 3) hydrosizer for particularly controlled separation of the sand which is completed by processing at a 4) dewatering screen and then passed to storage or delivery. Presenting the key components on a single chassis, and also arranging the components in-line on a chassis, is advantageous for many reasons as may be appreciated and as further described herein. Further aspects of plant  20  and the associated systems and methods of the invention are described. 
     In one aspect hydrosizer  30  is rotatably positioned on chassis  22 . The hydrosizer  30  is configured to receive material, including sand, entering from a top portion. Hydrosizer  30  also receives water through supply water pipes  61 ,  61   a . Hydrosizer  30  is a hindered settling classifier. Within hydrosizer  30  a column or layer of water pushes upward from the bottom area or middle portion of the hydrosizer  30 . The injection water travels at a rate such that only selected particles are carried upward and out of the hydrosizer  30  while heavier and/or larger material or sand particles drop to the bottom of the hydrosizer  30  and exit from a port at the bottom. Within the hydrosizer  30  materials are held in a state of “teeter” which comprises a narrow size band or area within the hydrosizer chamber. When particles that are larger (or heavier) enter the hydrosizer and into the band of teetering material, they drop to the bottom of the chamber and those materials that are finer or lighter are displaced to the overflow. By using an accurate sensing device with a constant flow of upward current water, well-defined separation of the input sand slurry is achieved. The pressure flow of water can be varied to alter the selected types or sizes of materials that are separated. In one aspect hydrosizer  30  may be a cone-styled hydrosizer  30 . It may be appreciated that a flat bottom hydrosizer may also be used. A taller cone-type hydrosizer  30  is more efficient than a flat bottom variety yet requires additional space and handling. 
     In one aspect hydrosizer  30  may be calibrated to separate sand within a desired range of sizes, such as hydrosizer may allow particles of 12 by 70 mesh to pass or drop downward to feedbox and then into dewatering screen. The 70 by 140 mesh sized particles will pass through the overflow port  68  of hydrosizer  30 . Hydrosizer may be configured so that the teeter point allows particles of sizes smaller or greater than 70 mesh to pass. The 12 by 70 sized particles may then be delivered to dewatering screen  42  for storage or delivery. The over flow from hydrosizer  30  may be further processed at a further cyclone separator and a screen to produce a  70  by 140 mesh sized product, for instance, and typically referred to as “100 mesh”. The overflow from hydrosizer  30  may be sent to a supplemental treatment facility  98  for further processing and to produce, for instance, 100 mesh product. 
     In one aspect hydrosizer  30  is positioned on base frame  24 . A hydraulic cylinder  34  is connected to base frame  24  and is configured to cause hydrosizer  30  to adjust between a generally horizontal orientation as shown in  FIG. 1  and  FIG. 2  and a generally vertical orientation as shown in  FIG. 3  and  FIG. 4 . Hydrosizer  30  may be selectively raised (or tipped upward) or lowered as desired. In further aspect a crane or hoist may be used to move the hydrosizer  30  into position (by pivoting as described below or otherwise). In one aspect hydrosizer  30  is mounted to or in a tower structure  36 . A top collar  31  is configured to receive hydrosizer  30 . In one aspect collar  31  surrounds hydrosizer  30  generally where hydrosizer  30  begins to taper. Tower structure  36  includes support legs  38 . Support legs  38  form a generally rectangular frame configured to hold and support hydrosizer  30 . In one aspect a set of four legs  38  will hold hydrosizer  30 . Cross supports  37  are used for structural support of tower  36 . Cylinder  34  may connect to a gusset plate  39 . Activation of cylinder  34  pushes against gusset plate  39  causing tower structure  36  to rotate upward in the direction of arrow A (See  FIG. 2 ). Tower  36  connects to base frame  24  at a pivot  35 . It may be appreciated that a pivot  35  is positioned on each side of chassis, and that two cylinders  34  may be utilized as desired. In one aspect pivot  35  includes a pin about which a support member pivots. Support leg  38 , via pivot plate  35 ′, pivots about pin  35 . In one aspect support leg  38  may rest upon base frame  24 . In another aspect support leg  38  may be slightly suspended from base frame  24  such that the pivot plate  35 ′ and pivot  35  provide the supporting structure for leg  38 . Support leg  38   a  includes a foot  33  which rests upon rear frame  28  when tower  36  is in an upright position. In an alternative aspect tower  36  may be positioned such that foot  33  rests upon base frame  24 . Positioning tower  36  so that leg  38   a  rests on rear frame  28  accommodates for a greater open space area on chassis  22  for placement of additional material processing devices. 
     It may be appreciated that use of pivot plate  35 ′ accommodates an efficient rotation of tower  36  while also allowing a clearance between hydrosizer  30  and chassis  22 . For instance, in horizontal mode, tower structure  36  includes a support leg  38  which is oriented generally parallel to and in a spaced relationship with base frame  24 . Leg  38  of structure  36  will engage with cradle  27 , for instance. In one aspect the meeting of leg  38  with cradle  27  (together with pin  35 ) is the only point of contact between structure  36  and chassis  22 . Such arrangement assists in creating clearance for hydrosizer  30  and related frames and structures from contacting chassis  22  during transport (to better protect against damage during travel). In one example the box  43 , (or cyclone  40  piping) for instance, will be maintained in a spaced relationship with respect to base frame  24  or elevated frame  26 . Leg  38  connects to pivot plate in an off-set orientation in that an axis extending along the longitudinal length of leg  38  does not intersect pivot  35 . Such offset due to use of pivot plate  35 ′ also accommodates horizontal translation of tower  36  to a position closer to elevated frame  28 . For instance, an axis extending along the longitudinal length of leg  38  when tower  36  is in an elevated mode is positioned closer to elevated frame  28  as compared to a vertical axis running through pivot  35 . Such horizontal translation accommodates leg  38   a  contacting elevated frame  28  and provides for greater clearance or space on the remaining portion of frame  24  to receive additional material processing components when tower  36  is raised. It may be appreciated that use of pivot plate  35 ′ minimizes or eliminates the support leg  38  from contacting base frame  24  prior to support leg  38   a  contacting rear frame  28 . 
     Positioned above hydrosizer is a separator  40  such as a cyclone separator configured to remove undesired or small-size materials before entering into hydrosizer  30 . In one example the small-size materials of the overflow from separator  40  may include particles of −140 mesh, for instance, particles that are smaller than, or would pass through a screen of 140 mesh. A 140 mesh screen has 140 openings per linear inch. A 140 mesh screen has a sieve size of 0.105 mm (or 105 microns). Operation of a cyclone separator is commonly known. Unwanted or small-size materials are moved upward from within separator  40  and outward through a conduit  41  and into a collection box  43  or to an out-hose for disposal or subsequent treatment. An out-hose may be connected to output port  43 ′. In some instances the unwanted or overflow output from separator  40  is delivered to a holding pond or to a UFR (ultra fines recovery) plant or system. In one aspect the overflow from separator  40  may contain a slurry of material having fine particles of the size less than 140 mesh. This overflow may be further separated by passing the material to another separator for a finer separation, to retain particles that are 140 mesh by 350 mesh, where the −350 mesh are discarded (i.e., discarded if small enough to pass through a 350 mesh screen, for instance). The 140×350 mesh particles are considered UFR (ultra fines recovery). 
     An overflow port  68  is provided at hydrosizer  30 . Materials may pass through overflow port  68  and also delivered to a holding pond or to a UFR plant or system. It may be appreciated that different types or sizes of materials may pass thorough overflow port  68  and output port  43 ′ and delivered to different (or the same) processing equipment or holding ponds. In other examples collection box may be positioned at overflow port  68  to combine the materials exiting cyclone  40  and hydrosizer  30 . Use of box  43  allows an operator an option of further treating the overflow from cyclone separator  40 , such as to further separate the overflow. 
     In one aspect, at or toward the second end  22   b  of chassis  22  is a sump  44  and a dewatering screen assembly  42 . Dewatering screen  42  is situated on or above sump  44 . In one aspect sump  44  is a 2000 gallon capacity sump configured to hold a slurry of sand and water. It may be appreciated that sump  44  may be configured of different capacities. Sump  44  in one aspect is positioned on top of base frame  24  and may extend generally rearward such that a portion may extend on or above rear frame  28 . Sump  44  may be connected (by welding, bolting or other secure fastening) to chassis  22  so that sump  44  is included on chassis  22  as chassis  22  is transported along a roadway. Having sump  44  oriented into a fixed position with respect to hydrosizer  30  and erected tower  36  accommodates for efficient set-up of sand plant  20 . For instance, sump  44  is mounted into position such that it is in close proximity to hydrosizer  30  which receives the slurry from sump  44 . Also, for compact location, a feed box  46  which supplies material to dewatering screen assembly  42  is positioned above sump  44  and immediately below hydrosizer  30  to conveniently receive material exiting from hydrosizer  30 . Moreover, placement of screen assembly  42  at least to partially overlap sump  44  provides further compact and in-line positioning upon chassis  22 . Setting sump  44  into position as shown reduces efforts for the set-up and assembly of plant  20 . Setting sump  44  as shown, together with placement of hydrosizer  30  and tower structure  36  onto chassis  22 , may be accomplished indoors at the manufacturing facility where a convenient crane and construction/assembly tools are available for efficient construction. Such pre-fabrication of components on chassis  22  accommodates a drastic reduction in the expense and time of set-up of a processing facility in the field. Screen assembly  42  may also be connected to chassis  22  and sump  44  for transport. Connecting screen assembly  42  to chassis  22  and sump  44  prior to transportation allows for easier set-up of plant  20  when it reaches a desired processing destination. Alternatively screen assembly  42  may be placed on sump  44  and chassis  22  after chassis  22  has been transported to a desired treating location. A feedbox  46  is positioned above dewatering assembly  42 . Material or sand exiting downward through a port at hydrosizer  30  enters inlet port  47  of feedbox  46  and into assembly  42 . In one aspect dewatering screen  42  is in part positioned above sump  44 . Having screen  42  at least partially overlap sump  44  allows for a more compact in-line arrangement of material processing devices placed on chassis  22 . 
     At second end  22   b  and beneath rear frame  28  is frame suspension  32 . Suspension  32  includes an axle or axles and typically a spring or other suspension mechanism. Wheels are placed on axles. Wheels accommodate portability and travel of plant  20 . Plant  20  may be transported down or on a roadway to a desired location. In one aspect suspension  32  may be disconnected from chassis  22 . Bolts  76  or other fasteners may be used to connect suspension  32  to chassis  22  and removed in order to remove the suspension  32 . Once detached, suspension  32  may be rolled away from chassis  22 . 
     It may be appreciated that when wheels and/or suspension  32  are removed, base frame  24  rests on a surface or the ground or on a slab  21  (such as a concrete slab) as desired. Allowing base frame  24  to rest upon the ground provides support and stability to plant  20 . Jacks  48  may be utilized with chassis  22  to stabilize and further support goose neck  26  and rear frame  28 . Jacks  48 ′, such as hydraulic jacks, are also used to raise second end  22   b , for instance, so that frame suspension  32  may be removed. Other mechanisms may also be used to raise second end  22   b , whether connected to rear frame  28  or otherwise. It may be appreciated that alternatively air may also be removed from wheels so that base frame  24  rest on slab  20 . As a further alternative wheels may be removed from axles so that base frame  24  rests on slab  20 . After frame suspension  32  is removed, jacks  48 ′ may be adjusted to lower second end  22   b  so that base frame  24  contacts ground or slab  21 . Jack  48 ′ may be adjusted so rear frame  28  is positioned generally horizontally. Jacks  48 ,  48 ′ also provide additional support to rear frame  28  as may be desired. Jacks  48 ,  48 ′ may also provide additional support to goose neck  26  as desired. Jack  48 ,  48 ′ at first end  22   a  are used to assist removal of chassis  22  from a tractor. In one aspect with respect to  FIG. 2  it is shown where the wheels extend below base frame  24  such that base frame  24  does not contact the roadway during transport. An air axle assembly may also be used with suspension  32  so that frame  28  may be raised/lowered with respect to the wheels during transportation to accommodate maneuvering of chassis  22  along roadways or upon trails having varying grades or undulations. 
     Placing base frame  24  directly in contact with the ground or on a slab allows plant  20  to be securely connected to the slab. Slab  21  may comprise reinforced concrete. Slab  21  may include pins which extend upward from slab. In one aspect base frame  24  includes pin ports configured to receive the pins which extend upward from slab  21 . Nuts or other fastener device may be threaded upon pins to securely fasten frame  24  to slab  21 . Pin ports may extend at intervals over the length and width of frame  24  to accommodate securing frame  24  along the entire length and width of the frame  24 . It may be appreciated that frame  24  also includes cross supports  25  as reinforced structural support to resist flex or bending of frame  24  during transport and also for greater structural support when frame  24  is affixed to slab  21 . 
     After base frame  24  is positioned on slab  24 , cylinder  34  (or cylinders  34 ) activate in order to raise tower structure  36  and hydrosizer  30 . Alternatively a crane or hoist or other mechanism may be used to move structure  36 . When hydrosizer  30  is in an upright position, base frame  24  presents a platform or available space for receiving additional equipment for use in material processing. Such additional equipment may be transported to the field location separately and assembled onto chassis  22 . It may be appreciated that such components may all be positioned in-line on chassis  22  which results in an efficient assembly and operation of plant  20 . It may also be appreciated that chassis  22  and the additional devices may be preconfigured such that mounting onto chassis  22  may occur by simple bolting of the devices to the chassis. Such components and devices are configured for drop-in-place connection (i.e., the components may be modular and simply bolted into their pre-set position. 
     In one aspect, a primary wet screen  50  is positioned on chassis  22 . Screen  50  may be located at first end  22   a . It may be appreciated in one aspect that the components may also be reversed, with screen  50  positioned at second end  22   b  and dewatering screen  42  positioned at first end  22   a  (and hydrosizer  30  and sump  44  positioned closer to first end  22   a  if desired). A dry sand feeder  52  receives material and sand which is delivered to wet screen  50 . A discharge slide  54  extends from screen  50  so that oversize materials can be removed from the system. For instance, slide  54  may project to a front side  51  of plant  20 . Dry sand feeder  52  may be positioned closer to back side  53  of chassis  22 . It may be appreciated that screen  50  may be positioned on chassis  22  such that discharge slide  54  extends instead to an opposite side of the chassis, i.e., screen  50  may be positioned such that discharge slide  54  is oriented toward back side  53  (See  FIG. 11 ). Ability to switch the orientation of screen  50  accommodates flexibility in placement of plant  20  (i.e., some location may not have enough room available to load material into sand feeder  52  from the back side  53  so they may wish to configure screen  50  so sand feeder  52  is positioned toward front side  51 , or vice versa. Such flexibility allows for better utilization of the space surrounding plant  20 . A pipe  56  leads to a primary sump  60 . If the position of screen  50  is rotated, pipe  56  may extend from an opposite side of screen  50  into sump  60 . Sand material is mixed and sized with water in wet screen  50  to form a sand/water slurry. The slurry is generally fed from screen  50  to sump  60  by gravity. A pump  62  transports the slurry to a separator  70 . Pump  62  may be powered by a gas engine. It may be appreciated that a sump is generally required to be used in conjunction with a pump so that a steady or constant volume of material or water or slurry is available for the pump to operate most efficiently. Separator  70  removes water from the slurry so that the slurry is of a desired consistency for efficient scrubbing at cells  72 . Desired sand product drops from separator  70  into tubs or attrition cells  72  which operate as scrubbers to scrub the sand. In general, cells  72  grind the sand particles together to remove clays or other matter from the sand particles. The slurry then drops to trough  74 . Trough  74  receives the slurry which exits through pipe  58  and into sump  44 . In an alternative aspect pipe  58  may instead comprise a transition box which matches an output at trough  74  configured to reduce resistance that may occur at the junction of pipe  58  and trough  74 . In one aspect trough  74  has a sloped bottom to assist in gravity delivery of the slurry to sump  44 . 
     The mechanical and fluid action of the separator  40 , tubs  72  and trough  74  allow for a desired flow of slurry to sump  44 . A slide  75  is positioned between a bottom outlet of separator  70  to deliver the sand/slurry to tub  72 . The sand/slurry delivered to tub  72  is relatively dry to accommodate scrubbing activity. Separator  70  removes water and small particles which flow upward and out through outflow pipe  71 . In one aspect the outflow material from outflow pipe  71  is delivered to trough  74 . Due to the nature of separator  70 , overflow pipe  71  is configured to include a length which spans from above separator  70  to a position six feet (in one example) below the discharge point of separator  70 . Use of a relatively long overflow pipe  71  causes separator  70  to create more vacuum (i.e., to draw material upward from separator  70 ) which results in a relatively dry or dense product. For instance, separator  70  causes water and smaller particles to be removed from the slurry and delivered to trough  74  where the water is remixed with the sand returning from the tubs  72  at slide  75   a . A longer length of outflow pipe  71  presents a greater suction which tends to allow separator  70  to more readily drawn water from the slurry within separator  70 . A tower structure  66  accommodates a greater length for pipe  71 . A rubber boot  79  at the bottom of separator  70  also tends to hold sand at the bottom location of separator which also tends to compact the sand for a denser discharge out the bottom of separator  70  and prior to entry into tub  72 . When a large enough mass of sand builds up at boot  79 , the boot will flex to allow the sand to release from boot  79  and enter slide  75 . In one aspect separator  70  includes a tower structure  66  configured to hold separator  70  at a desired position above trough  74  and/or tubs  72 . Separator  70  is oriented generally vertically for most efficient operation. The tower structure  66  and struts  73  accommodate such vertical orientation and positioning of separator  70  to efficiently deliver sand to subsequent components of plant  20 . It may be appreciated that platform  77  is oriented in an elevated position above base frame  24  by struts  73 . In one aspect, platform  77  and struts are bolted into position upon chassis  22 . 
     In one aspect with reference to  FIG. 4  and  FIG. 8 , the sand material slides down slide  75  from separator  70  into tub or attrition cell  72 , such as through slide port  75 ′, where it is scrubbed. The material is scrubbed to remove clays and organics or other unwanted materials from the sand particles. Inside tub  72  the material is scrubbed and circulated and flows through box  80  where it enters another attrition cell or tub  72  for further scrubbing and circulation. The sand exits the second tub  72  at port  75 ″ where it slides down slide  75   a  and into trough  74  for delivery to sump  44 . 
     As shown at  FIG. 8 , box  80  provides a path through which sand travels from a first scrubber  72  to a second scrubber  72 . Box  80  may comprise a metal conduit and in one aspect includes a rubberized layer to protect the inner metal surfaces. It may be appreciated that the rubberized layer wears over time due to the friction and passage of sand or other materials through box  80 . In one aspect, box  80  includes a box joint  82  where box  80  connects to a flange of an attrition cell port. Box  80  may be fastened, by bolts for instance, to the flange and removed as desired. In one aspect a gasket may be placed between box  80  and flange to prevent leaking. A box joint  82  may be included at opposite sides of box  80  so that box  80  may be connected and disconnected from each of the attrition cells  72 ,  72 . It may be appreciated that removal of box  80  can be difficult or nearly impossible to accomplish without first separating or sliding apart the attritions cells  72 ,  72  from each other (or sliding them further away from each other). In one aspect of the invention each cell  72  is associated with a separate cell plate  90 . For scrubbing module  85 , each cell  72  is connected to an individual cell plate  90  which is in turn connected to a support  86  of the module  85 . Support  86  may also comprise platform  77 , or vice versa. In one aspect, cell plate  90  includes an elongated slot  88  or elongated slots which receive fasteners that extend through slot  88 . A nut secures plate  90  in position on support  86 . It may be appreciated that plate  90  may slide when the nut or nuts are loosened upon threaded fasteners which extend through elongated slots. As respective plates  90  slide away from each other, the distance between cells  72 ,  72  increases, thereby allowing for separation of box  80  from respective joints  82  for removal of box  80 . After box  80  is repaired or replaced, cells,  72 ,  72  (or a single cell  72 ) may be moved to close the gap or shorten the distance between cells  72 ,  72 . The pins running through slots  88  may be securely fastened upon support  86  with nuts or other connector. It may also be appreciated that a bracket  88  may be connected to plate  90  and another bracket connected to support  86 , for instance, to accommodate adjustment of respective plates  90 . For instance, a threaded pin or worm gear may be positioned between respective brackets  88  so that a user may rotate the pin to accomplish lateral sliding of plate  90  and resulting adjustment or positioning of the respective cells  72 . It may be appreciated that adjustment of a single cell  72  may be accomplished to remove box  80  or adjustment of both cells  72 ,  72  may be utilized. It may also be appreciated that scrubbing module  85  may be picked up and placed onto position on scrubbing platform  87  as a single unit. 
     Various additional or substitute components may be used in conjunction with chassis  22 . The components added to chassis  22  comprise a material processing system of the invention. Because tower structure  36  raises to expose usable space at base frame  24 , and because base frame may be positioned directly on the ground of on a slab  21 , additional components may be added to chassis without unduly compromising the balance and stability of chassis  22  and operation of the system. The chassis and additional components may be modularly configured for efficient assembly/construction. The additional components may also be positioned in-line for efficient operation. The open arrangement of base frame  24  when tower  36  is raised allows for efficient assembly (and disassembly) of plant  20 . Such efficient and compact arrangement is also intended to enhance performance of the sand treating operation. The arrangement accommodates an in-line process. Components are spaced in close proximity with each other and oriented to utilize gravity as much as possible. Having a base frame  24  which is positioned on the ground allows for a lower orientation of sump  44  which in turn assists in creating a lower profile structure to conveniently utilize gravity in the process. Orienting a bottom of sump  44  to be positioned below a top surface  29  of rear frame  28  allows for other components to be positioned closer to the ground or slab. For instance, placing sump  44  on base frame  24  which is lower than gooseneck  26  and rear frame  28  allows trough  74 , tubs  72  and separator  70  to be positioned relatively low while continuing to utilize gravity to assist transport or circulation of the sand/slurry. Utilizing the open space on frame  24  when tower  36  is erected allows the separate modules or material processing devices to be efficiently placed and stabilized in-line on a frame structure secured to the ground or slab  21 , and allows close placement to the hydrosizer  30  and adjacent components. The in-line arrangement provides efficient use of available land/space at the processing location. Unlike many processing operations where components may radiate from the hydorciser in different and unpredictable directions and may span relatively long distances and occupy a rather large footprint, the components of the present system have a pre-arranged in-line and efficient location and are configured for ease of assembly. 
     Pump  64  transports the slurry of sand and water from sump  44  upward to separator  40 . Pump  64  may be powered by an engine. Struts  73  may be used to elevate trough  74 , attrition cells  72  and separator  70  as shown. In one aspect struts  73  allow for efficient flow of slurry to sump  44  by use of gravity and/or without separate pumps for delivery. 
     When the chassis  22  has been fastened to slab  21  and tower  36  has been erected, additional modules or components are connected to form plant  20 . Scrubbing module  85  (See  FIG. 8 ) may be picked up (by a crane or otherwise) and placed on scrubbing platform  87 . Separator  70  and tower structure  66  may be picked and placed onto platform  87 . Sump  60  may be picked and placed onto frame  24 . Primary wet screen  50  may be picked and placed onto frame goose neck  26 . 
       FIG. 5  presents a reverse angle perspective view of plant  20 , showing the various components mentioned herein. A water intake manifold  95  is connected to chassis  22  and is configured to receive water for operation of the systems and methods of the invention. Supply lines which travel from a pond or other water source may connect to manifold  95  for subsequent delivery of water to the various components of plant  22 . It may be appreciated that separate water supply lines may also be configured to supply water directly to components (such as primary wet screen  50  or other components) without having to draw water only from manifold  95 . A lift hook such as hook  96  (or multiple hooks  96 ) may be included on platform  77  for ease of picking and placing platform into position on chassis  22 . Plant  20  is equipped with various safety rails, ladders and other equipment. 
       FIG. 9 ,  FIG. 10  and  FIG. 11  show top view aspects of the present invention.  FIG. 9  shows chassis  22  with hydrosizer  30  and structure  36  in a lowered position upon chassis  22 .  FIG. 10  shows chassis  22  with hydrosizer  30  and structure  36  in an elevated position. It may be appreciated that a vast space  99  is available upon chassis  22  at base frame  24  and at goose neck  26  for placement of material processing devices. It may also be appreciated that placement upon chassis at space  99  allows for in-line arrangement of devices sufficient for a sand processing operation, while also maintaining abundant ground areas surrounding chassis  22  for placement of additional equipment or general clearance for maneuvering around chassis  22 . In one aspect a supplemental treatment facility  98  is positioned adjacent chassis  22  to enhance plant  20 . Facility  98  may be used to further separate material such as sand. For instance, the overflow material from hydrosizer  30  which exits port  68  may flow to a sump at facility  98 . The overflow may transport through hose  59 . A pump will deliver the overflow slurry to a screen for further separation, allowing the separated sand to discharge along a conveyor  97 , for instance. It may be appreciated that overflow from separator  40  may transport from box  43  through pipe or hose  59  to a second sump of facility  99 . The slurry may be pumped to a further screen for further separation of the materials. In this configuration multiple separations and grades of sand can be captured and separated in an efficient manner and with minimization of footprint of the work site. 
     The processing components of the present system may be bolted into position, thus avoiding expensive welding or other construction. Each module or component may be configured with hooks to be picked and placed into position on chassis  22  or upon platform  77 . As shown with reference to  FIG. 12 , quick-position or alignment pegs  92  and bolt  94  arrangements are used for ease of setting and bolting components to chassis  22  and in space  99 . For instance, a peg  92  may project from chassis  22  (or from a cross-support of chassis  22 ). A strut  73  may include a peg hole  93  which receives peg  92  for ease of alignment of strut  73  on chassis  22 . Once strut  73  (or an entire component such as platform  77 ) is set in position on chassis  22  (via easy alignment where a number of pegs  92  set through peg hole  93  such that the strut  73  abuts directly to chassis  22 , for instance) a bolt  94  may be secured into pre-set bolt holes formed in chassis  22 . The positioning of the pegs  92  and respective peg holes  93  and bolt holes allow an operator to efficiently and accurately place the components in the field. No welding or special measuring is required, further making the construction of plant  20  efficient. In a further aspect, a platform  77 ′, such as may hold a pump  64  upon chassis  22 , may also be connected to chassis with quick-position pegs  92  and bolts  94 . Such features allow for fabrication of device modules in a manufacturing plant for ease of use in the field. Moreover, the manufacture may occur during the winter months and constructed when the weather breaks for speed of set-up. This allows a surprising benefit of speed to set-up in the springtime so that sand processing can begin as soon as possible when the thaw breaks (allowing for truck travel on roadways). 
     In one method aspect, chassis  22  is prepared in a shop and preconfigured with hydrosizer  30  within tower structure  36  and pivotally connected to chassis  22 . Sump  60  is fastened to chassis  22  and screen assembly  42  is optionally connected by placement at least partially over sump  44 . The remaining components are prepared for modular and in-line assembly or connection onto chassis  22 . Thereafter, sand plant  20  is transported to a field site typically by a tractor truck. Chassis  22  may be a truck towable chassis or trailer. The plant  20  may be pulled down a highway and meets conventional regulations of the department of transportation so that special permits are not required (at least in some jurisdictions) for the transport. The site is prepared with a slab  21  if desired. In one instance slab  21  includes pins or threaded pins extending upward from slab  21  (such as steel or rebar or other devices extending upward through a concrete slab) or other connecting devices associated with a slab. Plant  20  may be secured to the pins or fastening devices so that it is securely mounted to slab  20 . Once plant  20  is positioned and/or mounted at slab  21  or a desired location, first end  22   a  is lowered such that at least a portion of base frame  24  contacts the ground or slab  21 . To do so it may be appreciated that jack  48 ′ at first end  22   a  is activated to support the weight of end  22   a  while goose neck  26  is disconnected from the tractor truck. In one aspect, second end  22   b  may be raised momentarily to disconnect goose neck  26  from the truck. Thereafter, once the truck is removed, goose neck  26  is lowered such that base frame  24  may at least in part contact slab  21 . Second end  22   b  is then lowered such that the entire or substantially the entire base frame  24  rests upon the ground or on the slab  21 . Frame  24  may then be connected to slab  21 . Alternative sequences may be followed for raising and lowering chassis and removal of the wheels so that base frame  24  (or at least part of base frame  24 ) rests on the ground or on a slab. 
     In one aspect end  22   b  may be raised by use of jacks  48 ′. Activating jacks  48 ′ raises end  22   b  which relieves force acting upon frame suspension  32 . Reducing the force applied to frame suspension  32  allows for frame suspension  32  to be removed from chassis  22 . In one aspect, bolts  76  which connect suspension  32  to rear frame  28  are removed from bolt holes  78  to allow for disconnection. As shown in  FIG. 7 , a pattern of bolt holes  78  may be established on a frame  32   a  of frame extension  32 . A bolt  76  passes through rear frame  28  and through bolt holes  78  to secure suspension  32  to a position beneath rear frame  28 . It may be appreciated that a variety of bolt patterns may be used, and that alternative fasteners or fastening mechanisms may be used to allow suspension  32  to be removed from or connected to chassis  22 . Once suspension  32  is disconnected from frame  28  it may be wheeled away for storage or for subsequent reconnection and transport. After suspension  32  is removed, second end  22   b  is lowered, for instance, by operating jacks  48 . Once second end  22   b  is lowered, the entirety or substantially the entire base frame  24  rests upon the ground or on the slab  21 . Base frame  24  also includes bolt holes positioned in heavy duty beams. Concrete may be drilled for insertion of wedge anchor bolts which run through frame  24  into the anchors/slab to secure plant  20 . Such anchoring provides additional overall stability to plant  20 , including desired stability especially due to the height of hydrosizer  30  and the potential to capture the wind. While in operation the weight of hydrosizer  30  will tend to provide sufficient stability, yet when hydrosizer  30  is not in operation or empty, it is desired to have the additional stability where chassis  22  is bolted to the ground. 
     While the Figures depict plant  20  having wheels and suspension  32 , it may be appreciated that the wheels and frame suspension  32  are not required in order to rest base frame  24  on the ground. Having base frame  24  on the ground enhances the stability of the chassis and allows for use of several components for use in the processing of the sand. The resting on the ground enhances support for use of a taller hydrosizer  30  and the additional components such as screens, sumps, separator, attrition cells, pumps and related connectors, conduits and accessories. 
     In a further aspect the invention includes a method of utilizing a sand plant  20  having a chassis  22  configured to support a tip-up hydrosizer  30  together with additional components for use in a sand preparation operation. One aspect of the method includes utilizing a sand plant  20  having a chassis  22  which rests directly on the ground and where the chassis  22  supports the processing equipment. The processing equipment may include components as stated above. The method further includes raising the chassis  22  in order to provide clearance for connection with a suspension, for instance a suspension such as suspension  32 . Chassis  22  may be raised by any means. In one aspect chassis  22  is raised by use of jacks  48 ′. Suspension  32  may be connected to rear frame  28  to support second end  22   b  and accommodate transportation of plant  20  from site to site for subsequent sand processing operations. 
     In operation, after the method of set-up of sand plant  20  is accomplished with erected hydrosizer and added components and conduits noted or desired, in one aspect sand is delivered to primary wet screen  50  to process the sand into a wet slurry. Water is added to the sand and undesired sizes of sand and other particles are removed at this stage. The sand travels to primer sump  60 . A pump  62  transports the slurry from sump  60  to separator  70  to remove excess water and materials to condition the slurry for use in attrition cells  72 . A hose or conduit generally represented by line  57  may be used to transport the slurry. The slurry transitions from cell  72  to cell  72  and to trough  74  and then into sump  44 . A pump  64  pumps the slurry from sump  44  to an input port  45  of cyclone separator  40 . A hose or conduit generally represented by line  59  may be used to transport the slurry. Separator  40  separates the slurry into desired sand which drops to hydrosizer  30  while the lighter undesired particles and liquid raise upward and to conduit  41  for disposal or further treatment. The sand exits a port at the bottom of hydrosizer  30  and into feed box  46  and then into dewatering screen assembly  42 . Dewatering assembly de-waters the sand. The sand may be discharged through a discharge chute  49 . 
     When a sand processing operation is completed at a given site the portable sand plant  20  may be transported to a new site. The various components, or some of them (such as primary wet screen  50 , primary sump  60 , separator  70 , tubs  72 , trough  74  and a pump  62 , for instance), are removed from the chassis  22 , the hydrosizer  30  is adjusted so that it lay upon base frame  24 . A U-cradle  27  is positioned on a rail of chassis  22  such as at base frame  24 . U-cradle  27  receives a support leg  38  of tower structure  36 . U-cradle  27  assist to align leg  38  and stabilize leg  38  (and tower  36 ) for transport. Multiple U-cradles  27  may be used. In one aspect u-cradle  27  prevents hydrosizer  30  or cyclone separator  40  or related parts from contacting chassis  22  directly, thus reducing the forces that might otherwise impact hydrosizer or other components during transportation. 
     In a further aspect of the material processing method, a first material processing device is moved from a generally horizontal orientation above a portable chassis  22  to a generally vertical orientation above the chassis  22 . A second material processing device is positioned on the chassis at a position previously occupied by the first material processing device. The second material processing device is configured to process material to be supplied to the first material processing device. In one aspect the first material processing device is a hydrosizer  30 . Other material processing devices may be utilized as the first material processing device. In one aspect a second material processing device may include one from a group including attrition cells, separators, sumps, pumps, dewatering screens, watering screens or separators, or other material processing equipment. In one aspect the second material processing device includes a wet screen  50  which is placed on the chassis  22 . In another aspect the second material processing device includes at least one attrition cell  72  which is placed on base frame  24  of chassis (or on platform  77  which is connected to base frame  24 ). The devices are aligned in-line along chassis  22 . The devices are bolted into position. Additional material processing devices may also be positioned on a platform extending upward from the vacated space. 
     The present invention provides a compact system for complete processing of sand. The system is easy to assemble and operate and results in sand being completely processed utilizing only the components positioned on the chassis. Removal of any of the key components from the system would result in an unfinished end product or product requiring further treatment. Positioning the key components (primary wet screen, at least one scrubber or attrition cell, hydrosizer and dewatering screen) on a single chassis which is also configured to transport at least the hydrosizer, presents a compact or small footprint which allows for convenient positioning of supplemental treatment facilities in close proximity. Configuring the hydrosizer  30  to tip into position on a transportable chassis greatly reduces the construction cost and set-up time of a plant, and configuring a pre-set area on the chassis for additional processing equipment for in-line and gravity assisted processing of sand adds further value and benefits. The system may be easily disassembled, transported, and reassembled for subsequent use. 
     The terms and descriptions used herein are set forth by way of illustration only and are not meant as limitations. Those skilled in the art will recognize that many variations are possible within the spirit and scope of the invention as defined in the following claims, and their equivalents, in which all terms are to be understood in their broadest possible sense unless otherwise specifically indicated. While the particular PORTABLE SAND PLANT SYSTEMS AND METHODS as herein shown and described in detail is fully capable of attaining the above-described aspects of the invention, it is to be understood that it is the presently preferred embodiment of the present invention and thus, is representative of the subject matter which is broadly contemplated by the present invention, that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims.