System and method of coating a proppant

{
  "publication_number": "US10023791B1",
  "country": "US",
  "kind": "B1",
  "title": "System and method of coating a proppant",
  "abstract": "A system for adding dust control solution to a vertically falling first stream of a substantially dry particulate proppant, where the first stream has effective diameter, the system including a stationary, generally horizontal, deflector plate with drop-off edge, the plate mounted into the stream whereby the proppant collides with the plate and cascades from the plate around the drop-off edge to create a second stream of the particulate proppant having the general shape of the drop-off edge with a stream thickness and nozzles for spraying dust control solution into the second stream.",
  "claims": [
    "1. A system for loading a mass of essentially dry, free flowing dust free proppant particulate material into a transport vessel for immediate transportation to the hydraulic fracturing site for use in a fracturing operation, said system comprises a loading device receiving a supply of said particulate material having a D99 particle size of 50-2000 microns for discharging said particulate material by gravity in a vertical downwardly, unrestrained first stream of free falling particulate material, said first stream having an effective diameter and extending from an upper location downwardly in a gravity controlled given path, a fixed generally flat and generally horizontal deflector plate with a peripheral drop-off edge having a selected shape larger than said effective diameter, said plate mounted in a position to intersect said given path of particulate material so the falling particulate material in said first stream drops onto said deflector plate, forms a plate protecting dead bed of particular material on said plate and then cascades downwardly from around the peripheral drop-off edge creating a second free falling stream of particulate material having horizontal shape conforming to said selected shape of said peripheral drop-off edge and a width where said effective diameter of said first stream as at least 5 times said width of said second stream; a plurality of nozzles located below said deflector plate and generally facing said second stream; a pressurized supply of dust control solution to supply pressurized dust control solution to said nozzles for spraying into said second free falling stream of said particulate material; and, said transport vessel being located below and in line with said second stream to accumulate from said free falling second stream a mass of said proppant particulate material spray coated with said dust control solution while remaining free flowing.",
    "2. A system as defined in claim 1 wherein said proppant is frac sand.",
    "3. A system as defined in claim 1 wherein said coated particulate material has a moisture content of less than 0.3 percent so it remains free flowing.",
    "4. A system as defined in claim 1 wherein said discharge device is a silo.",
    "5. A system as defined in claim 1 wherein said discharge device is a transloader.",
    "6. A system as defined in claim 5 wherein said transloader has an outlet structure and said drop-off edge of said deflector plate is not continuous and extends from a first point on said structure to a second point on said structure.",
    "7. A system as defined in claim 1 wherein said drop-off edge is generally circular and said second free falling stream is generally in the shape of a cone.",
    "8. A system as defined in claim 1 wherein said second stream width is less than 3 inches."
  ],
  "description_excerpt": "This application claims priority to provisional patent application Ser. No. 62/206,524 filed on Aug. 18, 2015 which is incorporated by reference herein.\n\nThe present invention relates to the art of coating a sand-like particulate or granular material previously processed into a proppant as used for hydraulic fracturing with a dust control solution and more particular to an improved system and method to decrease the cost and increase the efficiency of providing a generally dust free proppant at the fracturing site.\n\nFor many years the proppant industry has expended tremendous time and effort in research and development in an effort to provide a dust free proppant for hydraulic fracturing. The reasons for controlling the dust coming from a proppant, like frac sand, are well known in the fracking art. Some companies have directed attention to improving the solution, as disclosed in Vorderbruggen US 2013/0192835, incorporated by reference herein. In accordance with well-known techniques, the “new” solution developed by Baker Hughes was “sprayed” onto the granular proppant. Other companies have attempted to develop mechanisms for improving the various coating practices, such as the practice of spraying a proppant with a dust control liquid or solution. One such attempt is disclosed in McDaniels US 2015/0119301, incorporated by reference herein.",
  "cpc": [
    "C09K 8/805",
    "B01J 2/006",
    "B05D 1/02",
    "B65G 3/04",
    "B65G 65/40",
    "B65G 69/185",
    "B65G 69/188"
  ],
  "ipc": [
    "B01J 2/00",
    "B05D 1/02",
    "B65G 3/04",
    "B65G 65/40",
    "B65G 69/18",
    "C09K 8/80"
  ],
  "assignees": [
    "Covia Holdings LLC"
  ],
  "inventors": [
    "Daniel Corcoran",
    "Jeffery S. Hicks",
    "Phil Maupin"
  ],
  "filing_date": "2016-08-10",
  "publication_date": "2018-07-17",
  "grant_date": "2018-07-17",
  "priority_date": "2015-08-18",
  "application_number": "US-201615232912-A",
  "family_id": "62837375",
  "cited_by_count": 19,
  "citations": [
    "US3822866A",
    "US3949908A",
    "US4572378A",
    "US5846022A",
    "US6190105B1",
    "US20070209583A1",
    "US20080128528A1",
    "US20130192835A1",
    "US20160024360A1",
    "US9637671B2",
    "US20150119301A1"
  ]
}