Slurry Pipelines
Slurry Pipelines
Slurry Pipelines
September 200
Presentation Outline
• Short History
• Fluid Concepts
• Advances
September 200
Major Systems
September 200
Andrew’s Slurry Pipeline Test Facility
September 200
Historical Leaders
September 200
Typical Slurry Pipeline Applications
Mineral Ore Transport System
• large volume transport
• low to medium pumping head
• medium distance pipeline (20 to 50 km)
• used when a mine plant and concentrator can not be located near the ore bodies due to
terrain difficulty, or when the mine plant and concentrator is installed near the tailings
impoundment site.
Tailings Disposal System
• high volume solid transport
• low head to transport mine tailings to impoundment.
• Short distance pipelines (up to 5 km to 60 km)
Concentrate Transport System – A vital part of the mining system, as a poor delivery
system can affect the mines ability to market its product effectively.
• low volume transport
• at high pressure lines
• Long distance pipelines (25 to 1,000 km)
September 200
Advantages of Slurry Pipeline
September 200
Advantages of Slurry Pipeline
Slurry pipelines are economic
September 200
Advantages of Slurry Pipeline
Slurry pipelines are safer and more reliable
Long Distance Slurry Pipeline Availability
1.00
0.99
Availability
0.98
Typically, long distance slurry
0.97 pipelines are very reliable.
The plot shows that 0.50
0.96 probability corresponds to
0.9925 availability.
0.95
0.94
0.00 0.20 0.40 0.60 0.80 1.00
Probability
September 200
Advantages of Slurry Pipeline
Slurry pipelines are more environment-friendly
environment
May be buried
ROW is quickly reclaimed
September 200
Advantages of Slurry Pipeline
Rugged terrain
Steep slopes
September 200
Technical Considerations for Pipeline Design
acility Location
Site Elevation
Terminal Elevation
Pipeline Route
Ideal Pipeline Route & Profile
Constructability
Final Route
Site Location
Elev. 750m
September 200
Technical Considerations for Pipeline Design
Initial proposed route profile
Cost Est
Est:: $ 65.95 M
1400
Cost Est
Est:: $ 42 M Final Route
1300
1200
1100
SM1
1000
900
800
msnm
700
600
500
400
300
VS1
Site Location
Elev. 750m
200 Punta
Totoralillo
100
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120
km
September 200
Technical Considerations for Pipeline Design
Slurry Properties
Slurry Classification:
1) Homogenous – slurries are only pseudo-homogenous
pseudo and not truly
homogenous due to force of gravity and settling characteristics;
2) Heterogenous – the concentration of the slurry particles varies greatly from
top to bottom of the pipe’s cross section; and
3) Complex – not completely homogeneous nor heterogeneous
September 200
Technical Considerations for Pipeline Design
Slurry Properties
Slurry Properties considered:
a) For carrier Fluid (usually water but may be alcohol, liquid CO2, oil and fuels:
• Density
• Viscosity
• Bulk Modulus
• Vapor Pressure
b) For Solids
• Density (specific gravity)
• Shape
• Particle Size Distribution
• Surfactants
c) Mixture (Slurry)
• Settling characteristics
• Rheological characteristics
September 200
Slurry Properties
Rheogram comparison of selected constitutive equations for rheological models associated with
lurries. The most common rheological models used for conventional slurries are the Newtonian
model and Bingham-Plastic.
September 200
Technical Considerations for Pipeline Design
Slurry Properties
Slurry types based on physical properties:
1) Conventional Mineral Slurries – prepared as a consequence of their beneficiation process with a high
degree of concentration and particle size control.
2) Conventional Tailings - lack the high degree of concentration and particle size control. Therefore, the
tailings pipeline designer prepares for many scenarios using heterogeneous and homogeneous models in
order to account for all possibilities.
3) Non-conventional Slurries - are highly concentrated and are non-Newtonian, with most being significantly
non-Newtonian (e.g., fuels).
4) Thickened Tailings (paste) - It has the advantage of disposing of highly concentrated tailings and therefore
reduces the storage volume required. Also, it eliminates the need to install water reclaim systems.
September 200
Slurry Properties
The relationship between solids specific gravity and “conventional” slurry top
particle size and solid’s volume fraction.
VolumeFraction
1.5 0.30
conditions,
0.25
2) it will it not wear th
1.0 0.20 pipe bottom,
0.15 3) it can be shutdown
and restarted.
0.5 0.10
0.05
0.0 0.00
1.0 2.0 3.0 4.0 5.0
Solid's SG
September 200
Effect of Hedstrom Number
10.000
1.000 He = 0
0.100 Rec
0.010
0.001
1.00E+01 1.00E+02 1.00E+03 1.00E+04 1.00E+05 1.00E+06 1.00E+07
Re
September 200
Technical Considerations for Pipeline Design
Slurry Properties Reduced Viscosity vs. Concentration
120
pH=10:
100 Blue Line = Reduced h / m w/o flocculant, h / m (69%) = 66
Red Line = Reduced h / m with flocculant, h / m (69%) = 67
.
80
Reduced Viscosity
60
40
20
-
0.50 0.55 0.60 0.65 0.70 0.75
September 200
Technical Considerations for Pipeline Design
Slurry Properties Yield Stress vs. Concentration
500
450 pH=10:
Blue Line = Yield Stress w/o flocculant, Ty(69%) = 140 d/cm2
400 Red Line = Yield Stress with flocculant Ty(69%) = 260 d/cm2
Green and Black line are rheogram interpretation variations.
350
Yield Stress, dyne/cm2
300
250
200
150
100
50
-
0.50 0.55 0.60 0.65 0.70 0.75
September 200
Technical Considerations for Pipeline Design
OPERATING RANGE
Upgraded Pipeline
2.00
Throughput 1.90
Excess capacity range at 97.4% System Availability @ 64% Cw
Phase 3 Maximum Throughput 1.75 M t/y @
64%, 168.2 m³/h & 95% Availability
1.80
As rule of thumb, pipeline transport
A n n u a l T h r o u g h p u t , D r y T o n n e s x 1 ,0 0 0 ,0 0 0
Phase 2 Maximum Throughput 1.50 M t/y @ 64% & 144.0 m³/h
s required if: 1.70
1.60
• Throughput capacity is over Phase 1 Maximum Throughput
700,000 dtpa (1,900 tpd) 1.50
1.30 M t/y @ 64% & 125.0 m³/h Phase 3
1.20
• Social impact on large 1.10
Phase 1 Phase 3 Nominal Throughput 1.45 M t/y @ 62%
September 200
SLURRY PIPELINE DESIGN
September 200
Materials for pipelines
PUMPS
Piston Pump
Plunger Pump
Piston-Diaphragm Pump
September 200
Materials for pipelines
Slurry Valves
Low Pressure
High Pressure
September 200
Materials for pipelines
Pipe materials
Steel. Carbon steel is the principal pipe material used,, relatively inexpensive and easily obtained. The pipeline design
can choose from many grades of steel. Usually for low and moderate pressures Grade B material is used. For high-pressure
high
applications, high test line pipe material is used. These grades can vary from API 5L X42 to X70.
Rubber. Rubber is still the most commonly used in pipes, pumps, and other process equipment. It has provided good
service for slurries that are uniformly abrasive.
September 200
Materials for pipelines
September 200
Centrifugal Pump Station
September 200
Potential use in the Philippines
September 200
50 km
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50 km
September 200
Potential use in the Philippines
September 200
RAMU NICKEL LATERITE DEPOSIT
September 200
RAMU NICKEL LATERITE DEPOSIT
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Calapan
80 km
Sta. Cruz
September 200
Potential use in the Philippines
September 200
Sipalay
Hinobaan
20 km Colet
September 200
CONCLUSION
September 200
OUR OFFICES AROUND THE WORLD
BRASS USA (BEI)
BRASS CHILE
(BCSA)
BRASS CHINA
(BBeijing)
BRASS DO BRASIL
(BDBrazil)
BRASS PHILIPPINES
(BTI)
September 200