Patent ID: 12234084

DETAILED DESCRIPTION

Many different storage systems exist for storing proppants for hydraulic fracturing operations. In one example, a silo-style system incorporates a plurality of silos that are transported to a well site where the silos are erected and filled with proppant. The proppant may be delivered to the well site via a truck and trailer, and then conveyed or pneumatically transferred the silos for storage. When the time comes to hydraulically fracture the well, the proppant is dispensed from the silo(s) onto a conveyor or gravity fed and into the blender where it is mixed with water and other chemicals before being sent downhole. The silo systems are beneficial because they offer higher payload compared to other containerized systems. However, the silo systems are expensive, loading systems can be unreliable, and may require specialty equipment in order to erect and/or operate the system.

Containerized storage systems utilize smaller containers to transport and store proppant. Such systems are less expensive and can be safer than silo systems when it comes to reducing silica dust, for example. Additionally, containerized systems are more versatile, as the containers can be more easily moved between locations, and can even be directly coupled to the blender preventing the need for proppant conveyors (and therefore reducing silica dust). However, the containers are not able to hold as much proppant with holding capacities ranging from about 12 tons of proppant per box to around 25 tons of proppant per box. Additionally, containers often require specialized trailers for transport and/or discharge of proppant at the well site. In order to provide the required amount of proppant for a fracking operation, many delivery trucks may be required to deliver numerous containers, sometimes over 100 boxes, increasing the possibility for accidents. Once on location, the storage area for the boxes may be 10,000 square feet or more.

Systems and methods for utilizing a reloadable containerized storage system for a hydraulic fracturing operation are described herein. According to embodiments of the disclosure, a containerized system utilizes a plurality of containers known to the industry for storing proppant. A reloading system allows the containers to be reloaded such that fewer containers are required to be stored at the wellsite. Transportation of proppant to the reloader can be accomplished with any style of bulk material trailer including but not limited to grain style and pneumatic style trailers. Payloads with such trailers can be higher than traditional containerized sand trailers reducing the number of loads to location and environmental impact. Thus, the system blends the efficiencies of silo systems with the reliability and versatility of box systems.

Referring toFIG.1, a system100for reloading proppant containers includes a delivery vehicle102, a transloader104, and a reloading system106. The reloading system106, described in detail below, generally includes a bulk material storage bin110and a reloader130. In a highly generalized summary, proppant P for use in hydraulic fracturing operations is delivered to a wellsite via the delivery vehicle102and offloaded onto the transloader104which deposits the proppant P into the reloading system106for reloading containerized proppant units (or simply “containers”)150. The flow of proppant P from the vehicle102to the reloading system106is represented by the arrows inFIG.1. One or more components of the system100may be in data communication with and controllable by an automated control system200(FIG.6), described in more detail herein.

The proppant P may be dry proppant DP or wet proppant WP. The moisture content of the proppant P may impact the flow of the proppant P from the bulk material storage bin110into the container150(e.g., all other things being equal, wet proppant WP may flow from the bulk material storage bin110into the container150at a slower rate than dry proppant DP, and wet proppant WP may have a higher likelihood of getting jammed in the bulk material storage bin110relative to dry proppant DP). In embodiments, certain features and workings of the system100may be adaptively modified based on the moisture content of the proppant P. In other embodiments, one reloading system100may be configured exclusively or primarily for dry proppant DP and another reloading system100may be configured exclusively or primarily for wet proppant WP, in line with the teachings of the present disclosure. The term “wet proppant,” as used herein, refers to proppant P with a moisture content greater than or equal to one percent. The moisture content may be measured using Equation 1 below or using other suitable methods known in the art or developed in the future.

moisture⁢content⁢of⁢soil=(weight⁢of⁢moist⁢soil-weight⁢of⁢dry⁢soil)weight⁢of⁢dry⁢soilEquation⁢1

For instance, if the weight of moist soil is 102 g and the weight of dry soil is 90 g, the moisture content of this proppant P is 0.133 or 13.3%. As such, this proppant P may be characterized as wet proppant WP.

The delivery vehicle102can be any vehicle configured to deliver proppant P to the wellsite, such as a grain trailer, pneumatic trailer, and the like. Because the delivery vehicle102does not need to be specially configured, any available delivery vehicle, or multiple types of delivery vehicles, may deliver proppant to the wellsite. This is beneficial because the operator is not limited by the availability of specific types of trailers or drivers for such trailers. Typically, however, the trailer will have a hopper bottom designed for offloading material at the well site.

The transloader104may have a conveyer belt104A, a discharging device104B, a moisture content reader104C, and a controller104D.

The transloader104may be any conveyor-type known to those of skill in the art, for example, an RBT-style transloader, mobile conveyor or auger, or any other conveying mechanism. Regardless of the type, the transloader104receives the proppant material P from the delivery vehicle102and, via the conveyer belt104A and discharging device104B thereof, conveys the proppant material P to the reloading system106. Specifically, the conveyer belt104A may convey the proppant material P to the discharging device104B and the discharging device104B may convey the proppant material P to the bulk material storage bin110of the reloading system106. The proppant P may ultimately be conveyed from the bulk material storage bin110of the reloading system106to the container150as set forth herein.

The discharging device104B may be located at a distal end of the transloader104and may optionally be selectively movable in order to discharge the proppant P into a particular area of the bulk material storage bin110. The discharging device104B is discussed in more detail with reference toFIG.4.

The moisture content reader104C may be located on the conveyer belt104A of the transloader104and/or elsewhere (e.g., on the discharging device104B, within the bulk material storage bin110, et cetera). The moisture content reader104C may be any suitable sensor now known or developed in the future that allows for the moisture of the proppant P to be determined, e.g., so as to distinguish between wet proppant WP and dry proppant DP. In embodiments, the readings of the moisture sensor104C may be fed to the controller104D in a wired or wireless manner. The moisture content reader104C may, in embodiments, comprise a grouping of moisture sensors that are placed on the transloader104and/or reloading device106.

The controller104D may control the operation of the transloader104based, e.g., on input from the automated control system200. For example, the controller104D may control the operation of the conveyer belt104A (e.g., start, stop, speed up, or slow down the belt104A) and/or control the operation of the discharging device104B (e.g., cause the discharging device104B to convey proppant P to a particular area of the bulk material storage bin110) based on input from the automated control system200. The controller104D may, in embodiments, use the readings from the moisture content reader104C to identify the proppant P as one of wet proppant WP and dry proppant DP and communicate same to the automated control system200. In other embodiments, the controller104D may communicate the reading of the moisture content reader104C to the automated control system200and the automated control system200may determine whether the proppant P is to be categorized as dry proppant DP or wet proppant WP.

As noted above, the reloading system106broadly includes a bulk material storage bin110and a reloader130. The bulk material storage bin110is a storage vessel for holding and dispensing proppant material P to the containers150, and may be configured to temporarily store at least 50 tons of proppant. In embodiments, the bulk material storage bin110may hold 60, 70, 80, 90, or 100 or more tons of proppant.

Referring now toFIGS.2A and2B, the bulk material storage bin110includes a proppant receiving area110A and a proppant dispensing area110B. The proppant dispensing area110B may be proximate the reloader130relative to the proppant receiving area110A. Proppant P may be delivered by the transloader104, and specifically the discharging device104B thereof, to the proppant receiving area110A of the bulk material storage bin110. The proppant P may flow from the proppant receiving area110A down into the proppant dispensing area110B and into one or more of the containers150. The flow of the proppant P from the bulk material storage bin110into the containers150may be due to gravity, and as discussed herein, may be aided by vibration devices and the like as appropriate. The surfaces of the bulk material storage bin110may be configured to ensure that the proppant P flows from the bulk material storage bin110into the containers150at an appropriate rate such that the containers150are filled quickly and efficiently without spillage.

The proppant dispensing area110B may comprise one or more funnels (or proppant dispensing devices)111. While four funnels111are shown inFIG.2A, it shall be understood by those of skill in the art that the bulk material storage bin110may have fewer than four (e.g., one two, or three—such as shown inFIG.1) or greater than four (e.g., five or more) funnels111. Each funnel111defines an opening112in the bottom of the bulk material storage bin110through which proppant P is permitted to flow.

A gate116covers each of the openings112. Each gate116may be configured as a knife gate, butterfly gate, or the like. The gate116may be coupled to a regulator118(FIG.2B) that is operable to open and close the gate116to control the flow of proppant P from the bulk material storage bin110. The regulator118may be controlled hydraulically, pneumatically, electrically, or otherwise as is known to those of skill in the art. As described below, the regulator118may be in communication with the automated control system200(FIG.6) that controls the regulator118, and therefore, the position of the gate116.

A loading tube120may be secured around the opening112of each funnel111, and may be designed to expand and contract to deliver proppant P from the bulk material storage bin110. A distal end120D of the loading tube120may include a diffuser122, such as a witch's hat, to aid in spreading the discharged proppant P. The diffuser122may facilitate the even spread of the discharged proppant P into the container150. In embodiments, the expansion and contraction of the loading tube120may be controlled via the automated control system200.

As shown inFIG.2A, the bulk material storage bin110, and specifically the proppant receiving area110A thereof, may optionally be equipped with one or more partitions or dividers114separating the vessel110into sections115A,115B, and115C. Each section115A,115B, and115C may have associated therewith a solitary funnel111or a grouping of funnels111. The sections115A,115B, and115C may receive different proppant materials P for use in the fracking fluid (e.g., section115A and section115B may receive proppant P having different moisture contents). Two partitions114are disclosed in the figures; however, it will be understood by those of skill in the art that a single partition114, or more than two partitions114, may be situated within the bulk material storage bin110to create sections for receiving different types of proppant materials.

The dividers114, where employed, may be removable or may be fixed. Where the dividers114are removable, the bulk material storage bin110may be divided into one or more sections in line with the requirements of the job. For example, a divider114may be employed to create a section for housing and dispensing dry proppant DP and another section for housing and dispensing wet proppant WP. Dividers114may likewise be used to guide the proppant P into a particular container150. As such, different sections of the bulk material storage bin110may have the same type of proppant P.

The bulk material storage bin110may comprise one or more measurement devices113A and one or more actuating devices113B. The measurement devices113A and the actuating devices113B may be situated in the proppant receiving area110A, the proppant dispensing area110B (e.g., proximate the gate116), and/or at another suitable location inside the bulk material storage bin110.

In embodiments, at least one measurement device113A and at least one actuating device113B may be associated with each funnel111. Thus, whileFIG.2Ashows one measurement device113A and one actuating device113B associated with each funnel111, in embodiments, two or a different number of measurement devices113A and two or a different number of actuating devices113B may be associated with each funnel111. In embodiments, one funnel111may have a different number of measurement devices113A or actuating devices113B associated with it relative to another funnel111. In some embodiments, one or more measurement devices113A and/or actuating devices113B may be omitted.

The measurement device113A, in embodiments, is a sensing device that allows for the determination of a property of the proppant P associated with a particular funnel111and/or a section (e.g., section115A) of the bulk material storage bin110associated with that funnel111. The measurement device113A may, e.g., be a contact and/or non-contact height sensor, a volume-determining device, or other appropriate device for determining at least one property of the proppant P associated with a particular funnel111or section. For example, the measurement device113A may be a mechanical height sensor, a radar level measurement device, an ultrasonic level sensor, a LIDAR volume sensor, et cetera. The measurement device113A may, for instance, allow for a height and/or volume of proppant P in the funnel111to be determined, so as to ensure that the area of the material storage bin110associated with the measurement device113A is not overfull with proppant P or has an inadequate amount of proppant P.

The actuating device113B may be any device configured to facilitate the flow of proppant P from the material storage bin110, e.g., the funnel111thereof, into the container150. The actuating device113B may, e.g., be a pneumatic vibrator device, an electrical vibrator device, or other suitable device configured to urge the proppant P from the bulk material storage bin110into the container150. The actuating device113B may be controlled by the automated control system200. The actuating device113B may further be actuated manually by an operator as desired.

The bulk material storage bin110may include a controller113C, which may be housed within the bulk material storage bin110or at a suitable location outside the bulk material storage bin110. The controller113C may be in data communication with the automated control system200, and may interact with the measurement device113A, the actuating device113B, and/or the regulator118. For example, the controller113C may convey measurements taken by the measurement device113A to the automated control system200and control the actuating device113B and/or the gate116based on directions provided by the automated control system200. For instance, where the measurements from the measurement device113A indicate that the proppant P is not flowing through the funnel111into the container150or is flowing downstream at too slow a rate (e.g., at less than 1000 lbs per 30 seconds), the automated control system200may cause the controller113C to activate the actuation device113B to speed up the flow of proppant P into the container150and/or cause the regulator118to more fully open the gate116.

The automated control system200may further control the operation of the transloader104based on input from the measurement device113A. For instance, where the measurement device113A indicates that a particular section (e.g., section115A) is nearing capacity, the automated control system200may cause the discharging device104B of the transloader104to discharge proppant P to a different section (e.g., section115B).

The automated control system200may also regulate the speed of the transloader conveyer belt104A based on the measurements taken by the measurement device(s)113A. For example, where the measurement devices113A indicate the bulk material storage bin110is nearing capacity (e.g., the bulk material storage bin110is at 85% capacity), the automated control system200may, in communication with the transloader controller104D, reduce the speed of the conveyer belt104A and generate an alarm (e.g., an audible alarm, a visual alarm, an electronic communication delivered to a mobile device of an operator, et cetera) so that operation of the system100may be evaluated. The automated control system200may further halt the conveyer belt104A where the measurements from the measurement devices113A indicate the bulk material storage bin110is at capacity.

FIG.2Cshows an example funnel111in more detail. Each funnel111may be symmetrical (e.g., a left half of the funnel111may be a mirror image of the right half thereof). Alternately, the shape of the funnel111may be irregular and may be configured in line with the particular application. Not all funnels111need to be identical.

In embodiments, each funnel111may have at least one angled wall section111A and one angled wall section111B. The angled wall section111A may make an exterior angle α with a horizontal plane H and the angled wall section111B may make an exterior angle β with the horizontal plane H. The angle α may, in embodiments, be disparate from the angle β.

While not required, the angles α and β of the wall sections111A and111B, respectively, may be adjustable. For example, where the proppant P is determined to be dry proppant DP, at least one of the angle α and the angle β may be set to about thirty degrees (30°) as these angles α and/or β may allow for the dry proppant DP to freely flow from the material storage bin110to the container150at the appropriate rate. Alternately, where the proppant P is determined to be wet proppant WP, one or both of the angles α and β may be increased, e.g., to about forty degrees (40°) or more. The increased slope of the wall sections111A and/or111B may ensure the wet proppant P travels into the appropriate container150at the desired rate despite the moisture content of the proppant P.

The wall sections111A and/or111B, and therefore the angles α and/or β, may be adjusted manually. Alternately, the wall sections111A and/or111B may be motorized and a user may set the angles α and/or β or the automated control system200may automatically set these angles based, e.g., on the moisture content of the proppant P and its flow rate into the container150. In other embodiments still, the wall sections111A and/or11!B may be fixed. In these embodiments, a bulk material storage bin110may be created for dry proppant DP and a separate bulk material storage system110may be created for wet proppant WP such that the angles α and/or β of the wet proppant material storage system110are greater than the angles α and/or β of the dry proppant material system110. In some embodiments, certain funnels111of a solitary bulk material storage bin110may be designed for wet proppant WP and other funnels111of that same bulk material storage bin110may be designed for dry proppant DP.

Other changes may likewise be made to the system100based on whether the proppant P is dry proppant DP or wet proppant WP. For example, where the reloading system100is configured for wet proppant WP, the surfaces of one or more components that are to come into contact with the wet proppant WP may be coated with anti-friction coatings to reduce proppant surface tension and facilitate the flow of the wet proppant WP from the transloader104ultimately into the container150.

Moving on toFIGS.3-5B, the bulk material storage bin110may be supported on the reloader130. The reloader130includes a frame132defining a receiving area134. The frame132has a bottom surface135that contacts the ground when in use, and a platform surface or channel guide136for supporting one or more containerized proppant units150. A plurality of partitions138may extend between the platform surface136and a top of the frame132thereby defining a plurality of individual reloading (or loading) bays140A,140B, and140C. While three reloading bays (generally140) are shown inFIG.3, it shall be understood that the reloader130may have greater than or fewer than three reloading bays. For example, inFIG.4, the reloader130is shown as having four reloading bays140A-140D. The reloader130may, in embodiments, have a solitary reloading bay.

The bulk material storage bin110may be lifted to a position atop the reloader130using any lifting mechanism, including but not limited to a forklift, standard loader, crane, et cetera, such that each of the funnels111extends generally into (or above) a respective reloading bay140A,140B, or140C.

Each reloading bay140may include a load cell142configured to receive a container150. The load cell142measures a weight of the container150in real time. The load cell142may be incorporated into a one-size-fits-all table that can receive any container150. In embodiments, the load cell142may be incorporated into an adjustable channel guide143(FIG.1) configured to receive multiple types of containers150. Regardless, the load cell142may be in operable communication with the automated control system200to control the flow of the proppant out of the bulk material storage bin110and into the respective container(s)150based at least in part on the weight of the respective container(s)150. In other words, each load cell142measures the weight of the respective container150, and the position of the gate116(i.e., open, partially open, or closed) may be automatically controlled based on the weight of the container150. Further, the actuating device113B may be activated where the measurements from the load cell142indicate that proppant P is not flowing into the container150at a suitable rate.

Each empty container150may be placed into a respective reloading bay140using, for example, a forklift. When the container150is placed in the reloading bay140, a releasing mechanism141(e.g., hooks, magnets, etc.) on the reloader130may automatically open a fill port or hatch152on the container150such that the container150can receive proppant from the bulk material storage bin110.

To receive the proppant, the loading tube120may expand downwardly toward the open fill port in the container150. As illustrated inFIG.4, in embodiments, the loading tube120may expand into the container150through the open fill port, thereby reducing the amount of silica dust created by movement of the proppant. The tube120may have a sealing ring (e.g., rubber, fiber, etc.) that is configured to form a seal on top of the container150to reduce the amount of silica dust. The automated control system200may control the position of the loading tube120relative to the container150. In embodiments, the loading tube120may automatically lower when an empty container150(e.g., as determined by the load cell142) is placed into a reloading bay140and may automatically raise when the container150is filled.

When the load cell142determines that the container150is full, the gate116may be closed and a light155on the reloader130above the respective reloading bay140may be activated to alert a user that the container150is filled and ready to be removed from the reloader130. As described in greater below, a display may convey the weight of the box and may correspond with a computing device, such as a tablet or computer. Additionally, as the container150is removed from the reloader130, or prior to the container150being removed from the reloader130, the hatch152may be automatically closed via the releasing mechanism141. In embodiments, the weight of the container150may be indicated on the container150, using, e.g., an RFID tag, an electronic display meter, and/or using other means.

The reloader130may further include an enclosure148that generally wraps around the bulk material storage bin110and the top of the reloader130to control silica dust generated by the moving proppant. In embodiments, the enclosure148may include a vacuum unit149for further filtering the air around the reloader130.

The reloader130may be generally configured as a trailer for easy transport. Accordingly, the reloader may include a plurality of wheels144and a hitch146for connecting to a vehicle as is known to those in the art. The wheels144may be built into the trailer such that when the reloader130is in the working position, the bottom surface135contacts the ground and the wheels144are non-weight bearing. In embodiments, the reloader130may be a skid mounted unit that is transported on a separate trailer.

FIG.4shows the discharging device104B of the transloader104in more detail. In embodiments, the discharging device104B may have proppant dispensing arms105A,105B, and105C, and so on. While three arms105A-105C are shown inFIG.4, one of skill in the art will understand that the discharging device104B may include a greater or fewer number of arms.

In some embodiments, the arms105A-105C may be movable. The movement of the arms115A-115C may be effectuated manually or using automated devices (e.g., using actuating devices controlled by the automated control system200). A proppant dispensing arm (e.g., arm105A) may be moved and resituated to cause that arm to dispense proppant P into the appropriate area of the bulk material storage bin110(e.g., to cause arm105A to dispense proppant P into section115B instead of section115A). In embodiments, the slope of the arms105A-105A may be adjustable, e.g., may be increased when the proppant P is wet proppant WP to facilitate the transfer of the wet proppant WP from the transloader104to the bulk material storage bin110. The distal ends of the arms105A-105C may be provided with a diffuser or spreader, e.g., a witch's hat, to ensure that the proppant P is distributed into the bulk material storage bin110, and specifically the sections115A-115C thereof, relatively evenly.

Attention is now directed toFIG.6, which schematically illustrates an automated control system200for controlling the reloading system100. The system200includes a computing device210communicatively coupled (e.g., via wires or wirelessly over a network205) to the transloader104, the bulk material storage bin110, the reloader130, and optionally other computing devices. The computing device210includes a processor215communicatively coupled to a network interface220, at least one input/output device225, and memory230. The processor215operates software235housed in the memory230.

Processor215represents one or more digital processors. In some example embodiments, the processor215may be configured through particularly configured hardware, such as an application specific integrated circuit (ASIC), field-programmable gate array (FPGA), etc., and/or through execution of software to perform functions in accordance with the disclosure herein. Network interface220may be implemented as one or both of a wired network interface and a wireless network (e.g., Wi-Fi, Internet, Bluetooth, Cellular, etc.) interface, as is known in the art.

The input/output device225may include one or more input and/or output devices which may be embodied in a single device or multiple devices. The input/output device225may include a keyboard, a mouse, a stylus pen, buttons, knobs, switches, and/or any other device that may allow a user to provide an input to the system200via the computing device210. In some embodiments, the input/output device225may comprise a media port (such as a USB port, or a SD or microSD port) to allow for media (e.g., a USB drive, a SD or microSD drive, laptop memory, smart phone memory, etc.) to be communicatively coupled to the computing device210. The input/output device225may further include one or more visual indicators (e.g., a display), audible indicators (e.g., speakers), or any other such output device now known or subsequently developed. A user may functionally interact with the system200via the input/output device225.

Memory230represents one or more of volatile memory (e.g., RAM) and non-volatile memory (e.g., ROM, FLASH, magnetic media, optical media, etc.). Although shown within the computing device210, memory230may be, at least in part, implemented as a network storage that is external to the computing device210and accessed via the network interface220. The memory230may house software235, which may be stored in a transitory or non-transitory portion of the memory230. Software235includes machine readable instructions that are executed by processor215to perform the functions described herein. Memory230may additionally house a database240which may include, for example, information relating to features of the containers (e.g., specific features of specific containers such as the weight of an empty/full PropX® container, or general features such as the average weight of an empty/full, non-specific container). The database240may comprise additional information required to operate the system100, such as the appropriate rate of flow of wet proppant WP and dry proppant DP into the containers150, the funnel wall section111A and111B angles for wet proppant WP and dry proppant DP, the appropriate speed of the conveyer belt104A based on the moisture content of the proppant P, et cetera.

The computing device210may selectively communicate over the network205with the transloader104, the bulk material storage bin110, and the reloader130. The computing device210may further communicate with other components, such as a mobile device of an operator, and in embodiments, may cause operational data to be stored at a remote location, e.g., on the cloud.

In operation, the processor215of the computing device210may communicate with controllers associated with each of the transloader104, the bulk material storage bin110, and the reloader130. In some embodiments, some or all of the functionality of the controllers associated with the transloader104, the bulk material storage bin110, and the reloader130may be incorporated in the controller215of the computing device210. The computing device210may be situated within the system100(e.g., within an enclosure created in the reloader130or elsewhere) or may be remote from the system100.

As described above, the transloader104may have a conveyer belt104A, a discharge device104B, a moisture sensor104C, and a processor104D. The conveyer belt104A, the discharge device104B, and the moisture sensor104C may be in data communication with the processor104D. The processor104D may further be communicatively coupled to a network interface220T, which may in-turn be coupled over the network205to the processor215of the computing device210. In operation, the processor215may employ the software235and the processor104D to control the transloader104. For example, where the processor215determines that the bulk material storage bin110is nearing capacity, the processor215may, via the software235and the processor104D, slow down the speed of the conveyer belt104A. Similarly, the processor215may employ the software235and the processor104D to facilitate discharging of proppant P by the discharging device104B into the appropriate section115A-115C of the bulk material storage bin110. The readings of the moisture sensor104C may be communicated by the processor104D to the processor215; and, where the angled wall sections111A and111B are adjustable, the processor215may adjust these angled wall sections based on the moisture content of the proppant P, to ensure suitable delivery of the proppant (e.g., wet proppant WP) into the container150.

The bulk material storage bin110, as described above, may comprise measurement devices113A, actuating devices113B, regulators118, loading tubes120, and a processor113C. The processor113C may communicate via a network interface220B with the processor215, and the processor215may control the operation of the bulk material storage bin110and/or other components based on the software235. For example, where a measurement device113A indicates that the proppant P is not being conveyed to the respective container150at a desirable rate (e.g., is jammed), the processor215may cause the actuating device113B to be activated and/or cause the regulator118to more fully open the gate116. Or, for instance, where a measurement device113A indicates that the bulk material storage bin110or a section115A-115C thereof is overfull, the processor215may halt the conveyer belt104A and generate an alarm. As another example, the processor215may, using the software235, cause the loading tube120to expand downwardly into a container150for dispensing the proppant P therein.

The reloader130, as detailed above, may include a load cell142and a light155. The reloader may further comprise a processor130C and a network interface220R to allow for bidirectional communication between the reloader130and the processor215. For example, where the load cell142indicates that the container150is empty and ready to be refilled, the processor215may use this information to cause the regulator118to open the gate116and start the refilling process. Similarly, the processor215may cause the regulator118to close the gate where the load cell142indicates the container150is full (e.g., has reached a weight of a full container150as set forth in the database240), or partially open or close the gate based on the actual versus desired flow rate of proppant P into the container.

Thus, the automated control system200may control one or more components of the transloader104, the bulk material storage bin110, and the reloader130, to ensure that the containers150are refilled as desired.

FIG.7is a flow chart generally illustrating the application of software235for controlling the system100. At step702, the process begins. Optionally, at step703, a user inputs (e.g., via the input/output device225or a remote device) information about the container150(e.g., selects a type of container such that the computing device210can pull relevant data from the database240). At step704, a container150is received onto the load cell142and the loading tube120lowers to the container150. The load cell142registers the weight of the container150at step706, and the weight of the container150is sent to the computing device210(or is requested by the computing device210) at step708.

At step710, the computing device210compares the weight of the container150as determined by the load cell142to the expected weight of a full container150as stored in the database240. If the weight of the container150is less than the expected weight of a full container150, the computing device210controls the components of the system100to facilitate efficient reloading of the container150.

Step712may comprise one or more of a plurality of sub-steps, as described in greater detail herein. For example, step712may include causing the regulator118to partially open, partially close, or fully open the gate116, activating the actuating devices113B to urge proppant P into the container150where it is determined the proppant P is not flowing into the container150at a desirable rate, altering the angles of the wall sections111A and/or111B based on the moisture content of the proppant P, regulating the speed of the conveyer belt104A, et cetera.

Steps706-712are repeated until the load cell142registers that the weight of the container150is approaching the expected weight of a full container150, as outlined in the database240. When the load cell142registers that the weight of the container150is approaching the expected weight of a full container150, the process moves to step714, where the position of the gate116is adjusted to slow the rate of the proppant P from the bulk material storage bin110to the container150. Step714may be repeated as necessary until the load cell142determines that the container is full, at which point the process moves to step716. At step716, the tube120may be retracted. Then, at step718, the hatch152on the container150may be closed. Finally, at step720, the light155on the reloader130at the corresponding reloading bay140is activated to signal that the container150is ready to be removed from the reloader130. When the container150is removed from the reloading bay140, the process starts over. The process may begin again at step703with information being input into the system, or the process may skip to step704with a container150being loaded into a reloading bay140for filling. At each step in the process, relevant information, such as the weight of the container150, may be displayed via the input/output device225of the one or more computing devices210.

Each of the various components described herein may be powered using an external power source, such as a generator, a turbine, or pulling from powered system such as a containerized sand belt. However, any power source, or multiple power sources, may be utilized to provide power to the system.

By incorporating a system for reloading containerized sand units150as described herein, it may be possible to reduce the containerized sand footprint at the wellsite by reducing the number of containers needed by more than 30%. With fewer containers at the wellsite, it may be easier to track the containers at the wellsite. Additionally, it may be possible to reduce the amount of space required to operate the system100as compared to standard container systems.

Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the spirit and scope of the disclosure. Embodiments of the disclosure have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the disclosure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations are and contemplated within the scope of the disclosure.