proven experience and knowledge on building efficient frac ... · be extracted from one point on...

Confidential and Proprietary

Proven Experience and Knowledge on Building Efficient Frac Sand Plants


AGENDA • Introduction to IAC • Industrial Sand Rotary Dryer Technology versus general light

duty Dryers • Automation that significantly improves plant efficiency and

operational costs • Expansion-ability to grow with the market demand at a fraction

of the cost


Industrial Accessories Company IAC is a 32 year old EPC Contractor Organization, with principle headquarters in Mission, KS. As an EPC / Turnkey Industrial Contractor, IAC, in conjunction with our wholly own construction company, Adelphi Construction perform $150+ million projects typically in the following industries within North America, Latin America, and Mexico: • Frac Sand • Ethanol • Mining & Minerals • Steel • Food & Pharm • Petrochemical

• Power Generation • Cement • Lime & Gypsum • Iron & Steel • Plastics • Foundries


- Modular Frac Sand Plants - Air Pollution Control Equipment - Frac Sand Rotary Dryer/Cooler

- Patented Design - Bulk Material Storage Systems - Pneumatic and Mechanical Handling

Equipment - DSI / BPAC Flue Gas Acid Treatment

System and Test Rigs - Motor Control Centers

In addition to IAC EPC / Turnkey Construction Projects, IAC is unique in that IAC internally designs and engineers IAC OEM equipment product lines for industrial and utility clients. IAC OEM Product Lines:

About IAC

- Automated Controls, PLC / DCS - HMI Management and Software

Program - Dry Recirculating Acid Gas

Scrubber for SO2, SO3, and HCL Mitigation – patented process

- High Temperature Filtration Equipment

- High Pressure >15 psig Filters


IAC can provide all of these as EPCM with

our Construction Management Team

Design, Engineering, Service Rail Loadout & Transload Facilities

Dust Collector OEM DSI and ACI Mercury Scrubber System

Turn-Key Plants

Full Service EPC Company


Scale: 45 Frac Sand Plant Projects Built

Momentum: Awarded 7 Dry and Wet Frac Sand Plants

Follow Through: 2 Times more Completed Projects than our Nearest Competitor

Speed to Market: Two plants completed in parallel within 8 months total

Engineering Integrity: OKC plant reached 50% of capacity with 8 hours, 100% within 7 days

Value through Innovation: Dryer technology capable of achieving 34% additional production output

Operational Excellence: Comprehensive training, operations, and optimization programs

Frac Sand Experts


Expansion-Ability


Expansion-Ability – Long Term Planning


Asphalt Plant Drums not Designed for Sand Light Duty Dryers w/Short life

Concerns with General Duty Dryers


Light Duty Flights Welded Flights Difficult to replace

Concerns with General Duty Dryers


IAC’s Search for a Better Design In this unique combination co-current rotary dryer/cooler design, a partial amount of moist material is added to the dried but as yet un-cooled product, so the cooling effect is assisted by the evaporation of water from the moist proportion of the solid material. The heat from the dried solids is used for drying the partial quantity of moist solids. The entire energy consumed for heating the dryer as well as the entire amount of air for drying and cooling are significantly reduced. IAC recognized the advantages of this design and improved on it by incorporating concepts developed in the U.S. hot-mix asphalt industry in order to reduce both weight and complexity of the European design. IAC’s design has been awarded U.S. Patent 9,322,595.

IAC Innovation: Frac Sand Dryer



Design Considerations incorporated into IAC’s unique Patented Dryer/Cooler

• Requirement for heavy duty equipment (thick-walled design of the drum and internal flighting for long life, Abrasion resistance and high production levels)

• Internal flighting design that can be custom designed to suit the drying needs of various frac sand gradations and easily replaced

• Airstream speed through the drum is limited in order to minimize product carry-over and abrasion with lower horsepower consumption than fluid bed dryers

• Heavy tire, trunnion and drive requirements for 24/7 service reduces maintenance

• Co-current rotary design chosen in order to mitigate the inherent disadvantages found in counter-current designs

• Simple straight-thru design eliminating weight and controls complexity

14


Exhausting the air from the rotary dryer is a comparatively simple arrangement as the air only has to be extracted from one point on the drum casing. Either wet scrubbers or baghouse final collectors are used for dust control. In some cases a knockout chamber or cyclone collector can be either inserted or incorporated between the dryer exit and the final collector.


IAC’s patented combination dryer/cooler incorporates a second wet feed collar towards the end of the rotary drum located between the drying and cooling zones. Approximately 75-80% wet sand is admitted at the upper inlet end of the dryer near the burner flame as primary feed and 20-25% wet sand is admitted in the collar ahead of the cooler as secondary feed. U.S. Patent 9,322,595


Lifting and saw-tooth flights downstream of the combustion zone properly veils the sand through the hot gas stream providing very effective and efficient evaporation. These flights are alternated in order to provide a curtain of material preventing hot gases from circumventing the material. U.S. Patent 9,322,595


Interior shell liners and inlet chutes are fabricated from a specialized pre-hardened steel which is corrosion and heat-resistant to 1600 F. The shell is hardened to 500 BHN and polished to a #4 finish. Exterior shell protector plates, collar liners and scoops are all made of AR400 wear resistant steel. U.S. Patent 9,322,595


Dryer Inspection after several years of service


• IAC’s Patented Dual Feed Rotary Dryer/Cooler can perform under the most difficult conditions, including high moisture conductions, often above 10% moisture content.

• Drying and cooling both in the same drum. In the first stage, fed material dries down the length of the rotary barrel, and then adding up to 20% of additional feed can be added through a second feed for the final stage of cooling.

• Built with a thick-walled drum, abrasion resistant materials, and bolt in flighting for ease of replacement.

• Internal flight design is customizable to maximize drying efficiency of different products.

• IAC’s advanced automation controls, monitoring technology, and predictive modeling allow the plant to be operated with minimal staffing and standardized control.

• IAC is a leading-edge design, engineer, and erection company proving Turnkey Solutions for dry bulk material storage. Our experience in bulk storage silos, pneumatic material transfer, and dust filtration can provide you with a single source procurement and installation.

• Modular bolted storage silos offer flexibility to customize capacity up to 5,000 tons per silo.

• IAC is an OEM manufacturer of dry particulate collectors for process and nuisance dust control at all points during the processing and transportation of product. Our systems can meet the most stringent air quality control standards.

• Transfer your material faster without losing product.

• Screeners are built from abrasion resistant steel and efficiently separate product into storage silos resulting in high product yields.


IAC’s patented combination dryer/cooler performs both drying and cooling of fine sand within one rotary drum without changing the flow path of the sand, all while minimizing airflow requirements or complex controls found in fluid bed or other counter-current rotary dryers or dryer/coolers. U.S. Patent 9,322,595


Resin sand was greatly reduced in frac sand industry largely due to the high cost of coating when finer sands with higher K values were utilized. However, in Argentina, resin coating in basin sand with in adequate k values, can raise the crush strength to acceptable levels hence greatly reducing the existing transportation costs, and more than offsetting the overall cost/ton of the proppant resulting in significant savings.

Resin Coating Technology


IAC Automation and Optimization Services IAC is committed to provide each of our customers with a long term approach to success and maximum facility utilization. In order to accomplish this, we have put together programs that ensure success through continued training, effective preventive maintenance programs and on-site support. As an equipment supplier, we are often asked to sell or install equipment, but don’t provide the necessary continued support to ensure success. Each application is different, Dust are known for their abrasive nature. This carries over to bags, seals, etc., and can change with changing process conditions. Many facilities plants struggle to maintain consistent velocities, due to changing moisture applications. The program we are suggesting provides our team an opportunity to inspect and balance, assist in the maintenance and balancing of the systems on a more frequent basis. This type of inspection has a quick return on investment through increased uptime of the equipment and decreased wear. There are many changes that occur between startup and sustained operation. There can be a high turnover of people within the operations and training can often become lost as people transition. This is where we can supplement the team with experienced labor to assist in many areas. We would like to develop a plan where we provide an initial assessment and plan to ensure success.


Understanding When/Why To Automated? Define goals, financial objectives for automation and optimization • Increase overall profitability of company

• Increased production and plant utilization • Lower cost/ton produced • Reduce operating and utility costs • Planned shutdowns and Preventive Maintenance

• Increase/retain customer orders • Not only maintain consistent product output but increase output volumes to

customers • Reach new financial milestones • Increase Employee Retention and Productivity • Identify and maintain a competitive advantage • Improve financial marks perception of company • Maximize overall product yield of mine stockpile


Optimization with the help of Automation 1. Acknowledge where you are today as a baseline for improvement

a) Initially, avoid the shift in focus to where you need to be tomorrow! b) Put a team in the field and gather data and remove “perception” and “gut feel”

a) If you don’t have the systems, do it manually or hire a team to get and analyze the data! c) Characterize your current operating conditions vs. Original system design

a) Note the deviation from standard design and understand these control points. d) Model changes in operating conditions and how they effect the control points.

2. Identify the areas where you aren’t achieving maximum control point operation. a) Complete a process gap analysis and develop a plan to achieve existing control

point maximum sustained operations.


3. Determine which areas of the plant will improve by automation and remote monitoring. 4. Develop a stepped approach to implementation, so you can measure success

a) Set and communicate goals for steps to achieve a sustained operation based on optimal performance of the equipment, people and processes today

b) Implement, measure, report, modify, implement c) Report and celebrate steps in sustained production level increases

5. Adjust capital improvement plan, budget and timeline to increase production beyond control limits

Optimization with the help of Automation


Automation Process, Recap 1. Acknowledge where you are today as a baseline for improvement 2. Identify the areas where you aren’t achieving maximum control

point operation. 3. Develop a stepped approach to implement automation, so you can

measure success. 4. Adjust capital improvement plan, budget and timeline to increase production beyond control limits.


Automation

Advanced Technology: • Humidity Sensors • Thermocouples • Broken Bag Detectors • Pressure Transmitters • Remote Dashboards


Process: Varying Process Conditions

Dryer capability – actual operation to validate capability

• Profile WIP piles on moisture and gradation • Prove out maximum capacity with varying

moisture • Log data on pressure drops, temperature

profiles, etc.,

Screener capability • Develop data metric across screeners

• Quality impact fn (feedrate, gradation) • Screen configuration fn (gradation)

Conveyor and bucket elevator capacity • Ensure capacities fn (feedrate,

gradation)

Dust collection • Waste handling capacity f(feedrate,

gradation) • Pressure drop, dryer negative

pressure fn (feedrate, gradation) • ID fan performance curve fn

(feedrate, gradation)

Dry plant - Define current design and key “control points” in the system


Process: Data Analytics and Metrics Improved “control point” performance Process & procedural changes • Develop analytical tools which optimize

production at varying process conditions • Develop advanced controls package to

manage change in process conditions • Advanced trend and control charts to

characterize performance • Increased instrumentation and lab data. • Lag time reports to evaluate cause/effect

timelines for change.

Re-design and retrofit • Minimize pinch points with re-design and

retrofit • Develop capital strategy for optimization • Implement change and measure progress Measure and report progress at the front line to drive ownership • Measure and report performance by

individual, crew and business unit • Develop evaluation teams around

continuous improvement • Involve the front line on growth initiatives


Silos and Flat Storage with Loadout Truck Loadout


80/120/160 MTPH Frac Sand Plant Logistics


Feature Benefit 1) Modular Dry Sand Plant Installation at site in 8 weeks

2) Modular Wet Sand Plant Installation at site in 6 weeks

3) Dry Plant Delivery, 15 weeks Fast turnaround, includes 2wks ocean freight

4) Wet Plant Delivery, 17 weeks Fast turnaround, includes 3wks ocean freight

5) Dual Infeed IAC Sand Dryer Operates 95% efficient in wide moisture sand

ranges, low operator skillsets required 6) IAC Automated Controls Quick Start-Up and Commissioning

7) IAC Pre-assembled, Pre-wired MCC Minimal electrical wiring at site

8) Plant Operations performed by IAC IAC staff will operate plant while training owners

employees

80/120/160 MTPH Frac Sand Plant Project

THANK YOU INDUSTRIAL ACCESSORIES COMPANY

4800 Lamar Avenue

Mission, KS 66202

800.334.7431

www.iac-intl.com

proven experience and knowledge on building efficient frac ... · be extracted from one point on...

Documents