Method of reducing silicosis caused by inhalation of silica-containing proppant, such as silica sand and resin-coated sand, and apparatus therefor

Abstract

A method of reducing silicosis caused by inhalation of silica-containing proppant, such as silica sand and resin-coated silica sand, and apparatus therefor. The abstract of the disclosure is submitted herewith as required by 37 C.F.R. §1.72(b). As stated in 37 C.F.R. §1.72(b): A brief abstract of the technical disclosure in the specification must commence on a separate sheet, preferably following the claims, under the heading “Abstract of the Disclosure.” The purpose of the abstract is to enable the Patent and Trademark Office and the public generally to determine quickly from a cursory inspection the nature and gist of the technical disclosure. The abstract shall not be used for interpreting the scope of the claims. Therefore, any statements made relating to the abstract are not intended to limit the claims in any manner and should not be interpreted as limiting the claims in any manner.

What is claimed is: 
     
         1 . A method of reducing silicosis caused by inhalation of silica-containing granular material comprising a proppant, said method comprising the steps of:
 moving said silica-containing granular material comprising particles of different sizes from a first location to a second location;   during said moving, separating said particles of smaller sizes of said particles of different sizes into air and forming a crystalline silica dust cloud at at least one position between said first location and said second location;   at each said at least one position between said first location and said second location, removing a substantial portion of said dust from said crystalline silica dust cloud, with an arrangement for sucking away a substantial portion of said crystalline silica dust cloud and filtering the dust sucked away;   continuing moving said silica-containing granular material to said second location;   utilizing said silica-containing granular material as a proppant; and   said step of moving said silica-containing granular material comprises loading said silica-containing granular material into a storage container.   
     
     
         2 . The method of reducing silicosis according to  claim 1 , wherein:
 said method further comprises venting air from said storage container during loading of said silica-containing granular material and thereby venting smaller-sized particles of said silica-containing granular material into air and forming crystalline silica dust clouds; and   said step of removing a substantial portion of said dust from said crystalline silica dust cloud comprises sucking away a substantial portion of said vented smaller-sized particles.   
     
     
         3 . The method of reducing silicosis according to  claim 2 , wherein:
 said step of moving said silica-containing granular material comprises loading said silica-containing granular material into a blender and thereby separating smaller-sized particles of said silica-containing granular material into air and forming crystalline silica dust clouds; and   said step of removing a substantial portion of said dust from said crystalline silica dust cloud comprises sucking away a substantial portion of said smaller-sized particles in crystalline silica dust clouds adjacent said blender.   
     
     
         4 . The method of reducing silicosis according to  claim 3 , wherein:
 said step of moving said silica-containing granular material comprises:
 moving said silica-containing granular material from said storage container to a first conveyor belt; 
 moving said silica-containing granular material from said first conveyor belt to a second conveyor belt and thereby separating smaller-sized particles of said silica-containing granular material into air and forming crystalline silica dust clouds; 
 moving said silica-containing granular material from said second conveyor belt to a T-belt conveyor and thereby separating smaller-sized particles of said silica-containing granular material into air and forming crystalline silica dust clouds; and 
 moving said silica-containing granular material from said T-belt conveyor to said blender; and 
   said step of removing a substantial portion of said dust from said crystalline silica dust cloud comprises sucking away a substantial portion of said smaller-sized particles in crystalline silica dust clouds adjacent said conveyor belts.   
     
     
         5 . The method of reducing silicosis according to  claim 4 , wherein said steps of sucking away a substantial portion of said smaller-sized particles in crystalline silica dust clouds comprise:
 activating a vacuum system;   drawing air through intake openings of said vacuum system disposed adjacent the positions at which crystalline silica dust clouds are formed;   sucking air and crystalline silica dust through air ducts; and   collecting said crystalline silica dust in a collecting device.   
     
     
         6 . The method of reducing silicosis according to  claim 5 , wherein said step of sucking air and crystalline silica dust through air ducts comprises one of:
 sucking air and dust through air ducts connected to said storage container; and   sucking air and dust through air ducts disposed within and/or formed integrally with the body of said storage container.   
     
     
         7 . An arrangement for reducing silicosis caused by inhalation of silica-containing granular material comprising a proppant, said apparatus being configured to remove a substantial portion of crystalline silica dust from crystalline silica dust clouds formed from the moving of silica-containing granular material comprising particles of different sizes from a first location to a second location, said arrangement comprising:
 at least one intake disposed adjacent at least one position at which smaller-sized particles of silica-containing granular material are separated from particles of different sizes into air and form a crystalline silica dust cloud;   said at least one intake being configured to remove a substantial portion of said dust from an adjacent crystalline silica dust cloud;   an apparatus being configured to generate a vacuum force to suck in, through said at least one intake, a substantial portion of dust from an adjacent crystalline silica dust cloud;   an air duct arrangement being configured to conduct air and crystalline silica dust therethrough; and   a collection device being configured to collect crystalline silica dust received from said air duct arrangement.   
     
     
         8 . The arrangement according to  claim 7 , in combination with a storage container configured to store silica-containing granular material, wherein air ducts are disposed within and/or are formed integrally with the body of said storage container. 
     
     
         9 . The combination according to  claim 8 , wherein:
 said storage container comprises outlets covered by doors;   said doors being openable to permit air to vent through said outlets and to allow workers to monitor the fill level of silica-containing granular material in said storage container upon filling of said storage container with silica-containing granular material;   said at least one intake comprises a plurality of intakes, wherein one of said intakes is formed into a side wall of each of said outlets;   said storage container comprises a plurality of intake air ducts disposed beneath the roof of said storage container, wherein each of said intake air ducts is connected to a corresponding intake; and   said storage container comprises a main air duct arrangement connected to said intake air ducts, which main air duct arrangement comprises one of:
 a longitudinal air duct disposed adjacent a central portion of said storage container and to run along the length of said storage container; and 
 two longitudinal air ducts disposed along the sides of said storage container and to run along the length of said storage container. 
   
     
     
         10 . The combination according to  claim 9 , wherein:
 each of said storage container intakes comprises a valve configured to open and close said storage container intakes;   said intake air ducts are disposed transverse to the length of said storage container;   said storage container comprises an exhaust duct disposed at an end of said storage container and configured to conduct dust and air received from said main air duct arrangement of said storage container; and   said exhaust duct comprises a small air intake and a large air intake configured to be connected to a vacuum arrangement configured to collect dust produced by the transport of silica-containing granular material on a T-belt conveyor disposed transverse to the length of the storage container.   
     
     
         11 . The combination according to  claim 10 , wherein:
 said storage container comprises a conveyor belt intake and a lower connecting duct configured to connect said conveyor belt intake to said exhaust duct;   said conveyor belt intake is disposed adjacent a transition between a first conveyor belt and a second conveyor belt configured to convey silica-containing granular material from said storage container to a T-belt conveyor;   said conveyor belt intake is configured to collect dust produced by the transport of silica-containing granular material from a first conveyor belt to a second conveyor belt; and   said exhaust duct is configured to be connected to an exhaust duct of at least one other storage container to form a single exhaust.   
     
     
         12 . The combination according to  claim 11 , wherein:
 said plurality of storage container intakes are disposed in two groups;   said main air duct arrangement comprises said longitudinal air duct, which is disposed between said two groups of intakes; and   said storage container comprises an upper connecting duct configured to connect said longitudinal air duct to said exhaust duct.   
     
     
         13 . The arrangement according to  claim 7 , wherein:
 said collection device comprises a manifold having at least one air intake opening;   said air duct arrangement comprises:
 a plurality of tubes configured to operatively connect said collection device to said at least one intake; 
 at least one manifold arrangement configured to be connected by said tubes to a storage container to receive dust collected from a storage container; 
 connector arrangements connected to said manifold arrangements; 
 table arrangements configured to support said connector arrangements adjacent a storage container; 
 a ninety-degree step manifold arrangement configured to permit the making of turns with said tubes and a right or left hand orientation; 
 a dual-riser manifold arrangement and dual riser arrangements; 
 said dual-riser manifold comprises round tubing and rectangular mating flanges attached to said round tubing to permit the mating of said round tubing to said dual riser arrangements; and 
 said dual riser arrangements are configured to take the vacuum from the vacuum source and elevate the air or vacuum to a desired height; and 
   said air duct arrangement is configured to conduct air and dust into said manifold arrangements, then into said connector arrangements then into said ninety-degree step manifold arrangement, then into said dual-riser manifold arrangement, then into said dual riser arrangements, and then into said collection device.   
     
     
         14 . The arrangement according to  claim 13 , wherein:
 said air duct arrangement comprises a T-belt manifold arrangement configured to be disposed adjacent a blender at the end of a T-belt conveyor;   said T-belt manifold arrangement is configured to remove a substantial portion of dust from a crystalline silica dust cloud formed at at least one blender;   said air duct arrangement comprises a blender feed belt riser arrangement configured to take vacuum from said vacuum apparatus and elevate the air to a desired elevation;   said air duct arrangement is configured to conduct air and dust into said T-belt manifold arrangement, then into said blender feed belt riser arrangement, and then into said collection device;   said air duct arrangement comprises at least one tube connector configured to connect large diameter pipe with a steel, plastic, or aluminum alignment insert, an elastic water tight sock, and an elastic strap;   said collection device comprises air filter units;   said manifold further comprises a tube and an articulated duct; and   said articulated duct is articulated at a hinge and is movable by a hydraulic piston or arm to permit the upper portion of said articulated duct to be retracted downwardly for storage during the movement of said collection device, and to be extended upwardly to be connected to said air duct arrangement.   
     
     
         15 . The arrangement according to  claim 14 , in combination with a storage container configured to store silica-containing granular material, wherein air ducts are disposed within and/or are formed integrally with the body of said storage container. 
     
     
         16 . The combination according to  claim 15 , wherein:
 said storage container comprises outlets covered by doors;   said doors being openable to permit air to vent through said outlets and to allow workers to monitor the fill level of silica-containing granular material in said storage container upon filling of said storage container with silica-containing granular material;   said at least one intake comprises a plurality of intakes, wherein one of said intakes is formed into a side wall of each of said outlets;   said storage container comprises a plurality of intake air ducts disposed beneath the roof of said storage container, wherein each of said intake air ducts is connected to a corresponding intake; and   said storage container comprises a main air duct arrangement connected to said intake air ducts, which main air duct arrangement comprises one of:
 a longitudinal air duct disposed adjacent a central portion of said storage container and to run along the length of said storage container; and 
 two longitudinal air ducts disposed along the sides of said storage container and to run along the length of said storage container. 
   each of said storage container intakes comprises a valve configured to open and close said storage container intakes;   said intake air ducts are disposed transverse to the length of said storage container;   said storage container comprises an exhaust duct disposed at an end of said storage container and configured to conduct dust and air received from said main air duct arrangement of said storage container;   said exhaust duct comprises a small air intake and a large air intake configured to be connected to a vacuum arrangement configured to collect dust produced by the transport of silica-containing granular material on a T-belt conveyor disposed transverse to the length of the storage container;   said storage container comprises a conveyor belt intake and a lower connecting duct configured to connect said conveyor belt intake to said exhaust duct;   said conveyor belt intake is disposed adjacent a transition between a first conveyor belt and a second conveyor belt configured to convey silica-containing granular material from said storage container to a T-belt conveyor;   said conveyor belt intake is configured to collect dust produced by the transport of silica-containing granular material from a first conveyor belt to a second conveyor belt; and   said exhaust duct is configured to be connected to an exhaust duct of at least one other storage container to form a single exhaust.   
     
     
         17 . The combination according to  claim 16 , wherein:
 said plurality of storage container intakes are disposed in two groups;   said main air duct arrangement comprises said longitudinal air duct, which is disposed between said two groups of intakes; and   said storage container comprises an upper connecting duct configured to connect said longitudinal air duct to said exhaust duct.   
     
     
         18 . A method of handling pneumoconiosis-causing proppant, which proppant comprises sand, ceramic, or other particulates, said method comprising the steps of:
 selecting a proppant material having a grain size of between 12 to 140 mesh and having a sphericity, crush resistance, and solubility sufficient for use as a proppant;   blowing said proppant into a storage container;   during blowing, disturbing said proppant and forcing proppant dust into the air, and thereby generating at least one proppant dust cloud;   removing a substantial portion of said proppant dust from said at least one proppant dust cloud, with an arrangement for sucking away a substantial portion of said at least one proppant dust cloud, and filtering the proppant dust sucked away;   moving said proppant from said storage container to a blender;   during moving, disturbing said proppant and forcing proppant dust into the air, and thereby generating a proppant dust cloud at at least one position between said storage container and said blender;   at each said at least one position between said storage container and said blender, removing a substantial portion of said proppant dust from said proppant dust cloud, with said arrangement for sucking away a substantial portion of said proppant dust cloud, and filtering the proppant dust sucked away;   continuing moving said proppant to said blender; and   blending said proppant with fluid materials to form a mixture comprising about 95-99% water and about 1-5% proppant and other chemicals, which chemicals comprise at least one of:
 hydrochloric acid, 
 methanol propargyl, 
 polyacrylamide, 
 glutaraldehyde, 
 ethanol, 
 ethylene glycol, 
 alcohol, and 
 sodium hydroxide. 
   
     
     
         19 . The method of handling pneumoconiosis-causing proppant according to  claim 18 , wherein:
 said step of disturbing said proppant and forcing proppant dust into the air comprises venting air and proppant dust through outlets in said storage container; and   said step of removing a substantial portion of said proppant dust from said at least one proppant dust cloud comprises sucking air and proppant dust through a plurality of intakes, wherein one of said intakes is formed into a side wall of each of said outlets.   
     
     
         20 . The method of handling pneumoconiosis-causing proppant according to  claim 19 , wherein said step of removing a substantial portion of said proppant dust from said at least one proppant dust cloud comprises conducting air and proppant dust from said plurality of intakes through a plurality of intake air ducts disposed beneath a roof of said storage container, wherein each of said intake air ducts is connected to a corresponding intake, and then out through an exhaust arrangement.