KingCo achieves high-quality wet frac sand with EIW Falcon Sand Plant

KingCo developed its mine outside Kermit, Texas, with the goal of producing the best sand for its customers.

“We were trying to find equipment that would do what we needed in an efficient, cost-effective, clean manner,” said Jeffrey Thomas Olson, KingCo Energy Operations Engineer. “We were trying to make a clean product that came out dry, preferably better than anybody else in the industry.”

Olson researched his options and reached out to all the different manufacturers in the region, including Excel Machinery, the Eagle Iron Works dealer in Texas.

To meet KingCo Energy’s goals, Excel recommended the EIW Falcon Sand Plant, a modular washing and dewatering solution for producing drip-free, in-spec sand in a small footprint. It features a sump, pump and cyclones for washing the sand, as well as a dewatering screen for reducing the moisture content of the sand so it is ready for more immediate sale.

“The Eagle Iron Works Falcon was brought to our attention as something that was state-of-the-art basically in the industry,” Olson said. “It’s small, compact, and it fit the bill.”

When the Falcon Sand Plant arrived at KingCo Energy’s site in Kermit, Olson said it took two people about two days to put the plant together.

“From the time it was on the ground until we were pushing product out of it was less than two weeks,” Olson said.

Eagle Iron Works and Excel Machinery were on site for the startup of the Falcon Sand Plant to instruct the KingCo team on its operation.

“Working with Eagle Iron Works has been incredible. It’s been great. I call anybody on that team, and they have been very responsive.

“I can’t afford downtime, so having them be that responsive that been very nice for me,” Olson said. “They’ve taken very good care of us.”

As for operating the Falcon Sand Plant, one of Olson’s favorite things about it is its simplicity.

“The Falcon is extremely easy to operate,” Olson shared. “There’s really nothing to it. You turn it on and essentially walk away.”

KingCo Energy is pleased with the efficiency, operation and reliability of the Eagle Iron Works Falcon Sand Plant, which is producing around 250 tons an hour for the site.

“From Day 1, it has performed exactly how they told us it would,” said Olson. “It hasn’t missed a beat. Every sample that we have sent off and had tested has far exceeded anybody’s standards are far as what our sand quality needs to be, and it hasn’t required any work or maintenance to maintain that. It doesn’t matter what sand I put in, it puts out a good quality product at the other end.”

Additionally, KingCo Energy’s customers are “extremely happy” with the sand quality.

“They can tell the difference in our sand versus another client’s sand just by the way it looks on the ground after they’re done,” Olson said. “It’s dry. It’s clean.”

Olson reported the sand has a 7-8% moisture content coming off the belt after being processed through the Falcon Sand Plant.

“The product at the end of the day is extremely dry coming out of it, so our time from process to sale is quite quick,” shared Olson. “When I produce the sand, I can get it into a truck the next day instead of having to wait three to four days and having it take up space on our pad.

“We’re pretty much sellable as it comes off,” he said.

Being able to sell the sand quickly, Olson said, allows them to sell more and make more money.

“Product turn is important. We don’t make anything unless trucks are going out the driveway,” Olson said. “Product going out the driveway is what keeps our business going.”

Besides the simplicity of the Falcon Sand Plant, Olson also appreciates that its compact footprint gives KingCo the ability to expand operations, allowing the company room to add more equipment to increase production.

“The Eagle Iron Works Falcon has definitely met our needs for what we have planned on this site,” Olson said, “and we like the machine enough that we’re planning on getting another one.”