System and method of coating a proppant

Abstract

A system or method for adding dust control solution to a vertically falling first stream of a substantially dry sand-like particulate material, where the first stream has an effective diameter, the system or method includes a stationary, generally horizontal, deflector plate with a drop-off edge, the plate is mounted into the steam whereby the particulate material collides with the plate and cascades from the plate around the drop-off edge to create a second stream of the particulate material having the general shape of the drop-off edge with a reduced stream thickness and nozzles for spraying dust control solution into the second stream, which system or method is preferably for rapid transportation to the site for using the sand-like particular material.

1 - 29 . (canceled) 
     
     
         30 . A system for loading a mass of essentially dry, free flowing dust free sand-like particulate material into a transport vessel, said system comprises a loading device receiving a supply of said particulate material 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; 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 particulate material spray coated with said dust control solution while remaining free flowing. 
     
     
         31 . A system for loading a mass of essentially dry, dust free sand-like particulate material with a D99 particle site of 50-2000 microns into a transport vessel for rapid transportation to the site of use, said system comprises a particle discharge device receiving a supply of said particulate material and discharging a vertical downwardly, unrestrained first stream of free filling particulate material, said first stream having an effective diameter and extending from an upper location downwardly in a gravity controlled 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 material so the falling particulate material in said first stream drops on said deflector plate and then cascades downwardly from around the peripheral drop-off edge creating a second falling stream of particulate material having a horizontal shape conforming to said selected shape of said peripheral drop-off edge; 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 falling stream of said particulate material and a receptacle below said second stream to accumulate a mass of said particulate material coated with said dust control solution. 
     
     
         32 . The system defined in  claim 31  wherein said particle material is a proppant. 
     
     
         33 . A system as defined in  claim 32  wherein said proppant is frac sand. 
     
     
         34 . A system as defined in  claim 31  wherein said particulate material has a moisture content of less than 0.3 percent. 
     
     
         35 . A system as defined in  claim 31  wherein said discharge device has a particulate material outlet and said deflector plate is mounted below said outlet to define the general length of said first stream, with said general length being in the range of 6-24 inches. 
     
     
         36 . A system as defined in  claim 31  wherein said second stream has a width less than 6 inches. 
     
     
         37 . A system as defined in  claim 36  wherein said effective diameter is at least 5 times said width of said second stream. 
     
     
         38 . A system for adding dust control solution to a vertically falling first stream of a substantially dry sand-like particulate material, where said first stream has effective diameter, said system comprising a stationary, generally horizontal, deflector plate with drop-off edge, said plate mounted into said stream whereby said particulate material collides with said plate and cascades from said plate around said drop-off edge to create a second stream of said particulate material having the general shape of said drop-off edge with a stream thickness. 
     
     
         39 . A system as defined in  claim 38  wherein said stream thickness is less than ⅕ of said effective diameter. 
     
     
         40 . A method of coating a vertically falling first stream of a sand-like particulate material with a dust control solution, said first stream having an effective diameter, said method comprising converting said first stream into a second stream having a given shape with a thickness less than ⅕ of said effective diameter by intercepting said first stream with a stationary deflector plate having a drop-off edge defining said given shape; and, spraying said second stream with a dust control solution to produce a coated particulate material. 
     
     
         41 . A method as defined in  claim 40  wherein said shape of said second stream is a continuous shape. 
     
     
         42 . A method as defined in  claim 41  wherein said continuous shape is generally circular. 
     
     
         43 . A method as defined in  claim 41  wherein said spraying of said dust control solution is from the inside of said continuous shape. 
     
     
         44 . A method as defined in  claim 41  wherein said spraying is from the outside of said continuous shape. 
     
     
         45 . A method for preparing a substantially dry sand-like particulate material, said method comprising dropping said particulate material downwardly in first steam; intercepting said first stream by a dead bed fixed deflector plate to create a second falling stream; and, spraying said second stream with a dust control solution so the moisture content of said coated proppant is less than 0.3 percent. 
     
     
         46 . A method as defined in  claim 45  including catching said coated particulate material in a transportation vessel.