The present disclosure relates generally to proppant delivery for wellbore operations, and more particularly to a system and method for delivering proppant from a proppant source to a well site or a location remote from the well site.
Hydrocarbon-bearing subterranean formations may be stimulated by hydraulically fracturing the subterranean formation. A general fracturing operation may comprise pumping a fracturing fluid at a pressure above the fracture gradient of the subterranean formation. This pressurized fracturing fluid may then contact the subterranean formation to form one or more fractures. Some fracturing fluids utilize proppants to “prop open” and maintain separation of fractures that are created. Proppant materials can vary, but typically proppants are either sand-based or ceramic-based materials. A large amount of proppant is often needed on well sites that employ hydraulic fracturing. Often the components of a fracturing fluid are mixed or blended at the well site, and the components are delivered to the well site independently and stored.
When proppants such as sand are delivered to a well site, transportation costs may be significant. Depending on the method of delivery and handling of the proppant at the well site, the proppant may also create a dusty environment that may impede operations at the well site.
Illustrative examples of the present disclosure are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein, and wherein:
The illustrated figures are only exemplary and are not intended to assert or imply any limitation with regard to the environment, architecture, design, or process in which the different examples may be implemented.
In the following detailed description of several illustrative examples, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific examples that may be practiced. These examples are described in sufficient detail to enable those skilled in the art to practice them, and it is to be understood that other examples may be utilized, and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the disclosed examples. To avoid detail not necessary to enable those skilled in the art to practice the examples described herein, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the illustrative examples are defined only by the appended claims.
In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” Unless otherwise indicated, as used throughout this document, “or” does not require mutual exclusivity.
The present disclosure relates generally to proppant delivery for wellbore operations, and more particularly to a system and method for delivering proppant from a proppant source to a well site or a location remote from the well site. Earlier methods for delivering proppant to a well site involved transporting a bulk load of proppant to the well site and dumping or otherwise unloading the bulk load of proppant in a particular area. Many times the proppant would simply be placed on the ground or on a pad, and as needed, a material moving machine such as a front-end loader would access the bulk-stored proppant and transport loads of proppant to blend with fracturing fluid. This method of delivery created excessively dusty conditions at the well site, exposed the bulk pile of proppant to contaminants, and also resulted in reduced operational efficiency. It has become more common to use proppant containers at the well site to store proppant, and proppant is now typically delivered to well sites by trucks over long distances that carry the proppant containers already filled with proppant. The proppant containers are unloaded at the well site and stored for future use. Use of proppant containers may provide certain advantages at the well site for storage and use of the proppant, but a problem is presented due to the restrictions placed on vehicles and their loads when traveling on public roadways. Transport vehicles are limited to a particular cargo weight limit, which may be 80,000 pounds or even less in some areas. Since the proppant containers weigh a substantial amount, transportion of the containers with the proppant pre-loaded in the containers decreases the amount of proppant that may be transported from the proppant source to the well site. This combination of container, proppant, and transport trailer weight creates a payload disadvantage since less proppant can be hauled by a single vehicle. This disadvantage is amplified as the distance from the sand source to the well site is increased.
The systems and methods described herein provide a first vehicle that receives a load of proppant from a proppant source and transports the load of proppant without dividing the proppant load into individualized containers that must be carried by the first vehicle. Instead the proppant is carried by a first container on the first vehicle that holds the entire proppant load. After transporting the load of proppant from the proppant source to a location, a portion of the proppant load is delivered from the first container to a second container carried by a second vehicle. The second container is a smaller container than the first container and is used to store the proppant at the location. The second container is loaded with proppant without removing the second container from the second vehicle, thereby reducing “container touches,” reducing average fill time and improving efficiency.
Fracturing fluids may be prepared at a mixing area 124 of the well site 110. The mixing area 124 may include a plurality of mixing units 128 capable of mixing and blending the various components that are combined to form the fracturing fluid. The components may include water, chemicals and proppant. A water source 132 such as a tank may be positioned at the well site 110 to feed water to the mixing area 124. Water storage tanks 136 may be used to store water for the fracturing fluid near the mixing area 124.
The proppant source may be any location at which proppant may be procured or obtained. In some instances, the proppant source may be a sand mine. In others, the proppant source may be a facility that processes the proppant prior to its use in a well. Still other sources for the proppant are possible. The proppant source in many cases may be a great distance (50-100 miles or more) from the well site. Because of this distance and the regulations dictating weight limits for over-the-road transportation of bulk materials, it is advantageous to maximize the amount of proppant carried by the transport vehicle. As discussed in more detail below, maximizing the amount of proppant that can be legally carried by the transport vehicle means carrying the proppant in a large single container and not in individual smaller containers that would weigh more collectively than the large single container.
A proppant storage area 140 may be provided to store proppant that is to be mixed or blended in the mixing area 124 to create the fracturing fluid. The proppant may be stored in proppant containers 144 that are generally cube shaped but could instead be cylinders. Preferably the containers 144 are small enough to be easily movable by forklift or other material handling devices. The containers 144 may be stackable to allow for more efficient storage, and in some embodiments, the containers may have lids or covers. The proppant stored in the storage area 140 may be any type of proppant used in subterranean wells for hydraulic fracturing purposes. The type of proppant used may vary depending on the formation being fractured, but common examples may be sand-based proppants or ceramic-based proppants. It is possible that different types of proppants may be stored in the proppant storage area 140 if it is anticipated that different formation characteristics will be encountered during fracturing of the well 110.
The proppant delivery system 100 is deployed at or adjacent to the well site 105 and may be positioned proximate the proppant storage area 140, although this is not necessarily required. Examples of the proppant delivery system 100 are described in more detail below with reference to
The remote location 208 is preferably at least 2500 feet away from the well site 205, but in many cases, may be substantially more. In some embodiments, the remote location 208 may be a mile or even more from the well site 205. The remote location 208 is substantially closer in distance to the well site 205 than the proppant source, and this difference in distance highlights the advantage of the proppant delivery system 200 described herein. By transporting proppant from the proppant source to the remote location 208 (or in the case of
The proppant delivery system 300 may further include an intermediate storage bin 324 at the well site 105 or remote location 208 to receive the load of proppant 320 from the first container 316 of the first vehicle 312. The load of proppant 320 may be delivered from the first container 316 to the intermediate storage bin 324 by a conveyance device 328. The conveyance device 328 may be a conveyor belt that is driven by an electric motor or alternatively by a mechanical engine such as a gasoline or diesel engine. In other embodiments, the conveyance device may be a closed duct through which pressurized air or other gases are circulated to push the proppant through the duct and into the intermediate storage bin 324.
In the embodiment illustrated in
The intermediate storage bin 324 may be elevated above ground level as shown in
In each of the unloading and transferring operations discussed herein, the immediate area surrounding the release of proppant made be shrouded or otherwise covered or contained to reduce the presence of dust at either the well site 105 or the remote location 208.
The second container 425 may be smaller than the first container 316 and is meant to be able to carry only a portion of the load of proppant carried by the first container 316. In an embodiment, the portion of the load of proppant received into the second container 425 from the first container 316 is less than one fourth of the load of proppant carried by the first container 316. In other embodiments, the portion of the load of proppant received into the second container 425 from the first container 316 may be greater or less than one fourth of the load of proppant carried by the first container 316. The second container 425 is preferably made of materials that allow the proppant to be stored at the well site 105. In some embodiments, the second container 425 may be cube shaped while in other embodiments, the second container may be cylindrically shaped. Preferably, the second container 425 is stackable on other containers of similar design, which allows the containers to be more efficiently stored in the proppant storage area 140 of the well site 105.
While the second container 425 may in some embodiments be smaller than the first container 316, in other embodiments, the second container 425 may be the same size as or larger than the first container 316. Such embodiments may provide favorable conditions for having a larger second container 425, such as having a road or travel surface on which the second vehicle 415 travels that is not load limited. Such roads may include private roads or other roads that are not regulated as to the total amount of load that may be carried by a single vehicle.
The second vehicle 415 (e.g., the forklift) illustrated in
In yet another embodiment, the second vehicle 415, especially when positioned at or near the well site 105, may be a conveyance device (not shown but similar to the electrically or mechanically-driven conveyors described previously) that is used to carry and transport the second container 425. The second container 425 would remain on or attached to this conveyance device during the loading of the second container 425 with proppant and would then be capable of delivering the second container 425 with proppant to either the proppant storage area 140 or the mixing area 124. In an embodiment, the conveyance device may be a conveyor belt that carries the container. In another embodiment, the conveyance device may be an overhead container mover such as, for example, the container handling equipment used to load and unload containers in ship yards and ports.
Referring now more specifically to the embodiment illustrated in
The second container 525 is smaller than the first container 316 and is meant to be able to carry only a portion of the load of proppant carried by the first container 316. In an embodiment, the portion of the load of proppant received into the second container 325 from the first container 316 is less than one fourth of the load of proppant carried by the first container 316. The second container 525 is preferably made of materials that allow the proppant to be stored at the well site 205. In some embodiments, the second container 525 may be cube shaped while in other embodiments, the second container may be cylindrically shaped. Preferably, the second container 525 is stackable on other containers of similar design, which allows the containers to be more efficiently stored in the proppant storage area 140 of the well site 205.
While the second container 525 may in some embodiments be smaller than the first container 316, in other embodiments, the second container 525 may be the same size as or larger than the first container 316. Such embodiments may provide favorable conditions for having a larger second container 525, such as having a road or travel surface on which the second vehicle 515 travels that is not load limited. Such roads may include private roads or other roads that are not regulated as to the total amount of load that may be carried by a single vehicle.
The second vehicle 515 (e.g., the truck or truck and trailer rig) illustrated in
In addition to the embodiments and examples of a proppant delivery system and method provided above, the following are additional illustrative examples.
Example 1. A proppant delivery system for delivering proppant to a well site comprises a first vehicle having a first container configured to carry a first load of proppant and deliver the first load of proppant to a location; and a second vehicle configured to deliver a second container at the location to receive a portion of the first load into the second container, the container remaining on the second vehicle during loading of the second container.
Example 2. The system of example 1, wherein the location is a well site at which the proppant will be used to fracture a well.
Example 3. The system of example 1, wherein the location is a location remote from a well site at which the proppant will be used to fracture a well.
Example 4. The system of any of examples 1-3, wherein the second container is smaller than the first container.
Example 5. The system of any of examples 1-3, wherein the second container is larger than the first container.
Example 6. The system of any of examples 1-5, wherein the portion of the first load received into the second container is a less than one fourth of the first load.
Example 7. The system of any of examples 1-6, wherein the second container is stackable on other similar containers at the first site to store the proppant for later use.
Example 8. The system of any of examples 1-7, wherein the portion of the first load is delivered into the second container by an intermediate storage bin positioned above the second container.
Example 9. The system of any of examples 1-8, wherein the portion of the first load is delivered into the second container by an electrically, mechanically or pneumatically- driven conveyance device.
Example 10. The system of any of examples 1-9, wherein the first vehicle is a truck.
Example 11. The system of any of examples 1-10, wherein the second vehicle is a forklift.
Example 12. The system of any of examples 1-11, wherein the second vehicle is an electrically or mechanically-driven conveyance device.
Example 13. A method of delivering a proppant to a well site, the method comprises delivering a first load of proppant to a location; delivering a portion of the first load into a second container while the second container remains on a mover; and transporting the second container on the mover to a storage area.
Example 14. The method of example 13, wherein the location is a well site at which the proppant will be used to fracture a well.
Example 15. The method of any of examples 13-14, wherein the location is a location remote from a well site at which the proppant will be used to fracture a well.
Example 16. The method of any of examples 13-15, wherein the portion of the first load delivered into the second container is a less than one fourth of the first load.
Example 17. The method of any of examples 13-16, wherein the second vehicle is a forklift.
Example 18. The method of any of examples 13-17 further comprising delivering the first load of proppant into an intermediate storage bin prior to the portion of the first load being delivered to the second container; wherein delivering the portion of the first load into the second container further comprises dropping the portion of the first load from the intermediate storage bin into the second container.
Example 19. The method of any of examples 13-18, wherein delivering the portion of the first load into the second container further comprises moving the portion of the first load into the second container using an electrically, mechanically or pneumatically-driven conveyance device.
Example 20. The method of any of examples 13-19 further comprising stacking the second container on another similar container at the storage area.
Example 21. A proppant delivery system for delivering proppant from a proppant source to a location, the system comprising a first vehicle having a first container configured to carry a first load of proppant from a proppant source and deliver the first load of proppant to a location over at least one roadway; and a second vehicle configured to move a plurality of second containers at the location, each of the second containers configured to receive a portion of the first load until the first load is removed from the first container, each of the second containers remaining on the second vehicle while being loaded; wherein the location is a well site at which the proppant will be used to fracture a well, or a site remote from the well site; wherein the second container is smaller than the first container; wherein the portion of the first load received into the second container is less than or equal to one fourth of the first load, and the plurality of second containers comprises at least four second containers; wherein the second vehicle is a forklift.
Example 22. The system of example 21, wherein the portion of the first load received by each of the second containers is delivered by an intermediate storage bin positioned above each second container as the second container remains on the second vehicle.
Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the following claims.