LONG DISTANCE MINERAL TRANSPORTATION BY PIPE LINE

Abstract: A method of transportation of mineral ores by pipeline. The method comprises the steps of crushing the ore into relatively fine particles, mixing (3) the crushed ore with a liquid carrier to form a relatively high density mineral slurry, injecting a gas to aerate the slurry and produce a relatively low density mineralised froth, and pumping (5) the aerated slurry and froth along a fluid pipeline (6). A corresponding apparatus is also provided.

Description: TITLE: LONG DISTANCE MINERAL TRANSPORTATION BY PIPE LINE FIELD OF THE INVENTION The present invention relates to mineral transportation, and in particular to the transportation of heavy minerals by pipe line. BACKGROUND OF THE INVENTION In the mining of minerals such as coal, zircon, rutile, gold, copper, zinc, bauxite, and the like, the transportation of ore as well as the refined minerals often amounts to a significant proportion of the overall production cost. Conventional transportation systems include road links, rail networks, and ships. However, these are relatively inefficient and place considerable demands on environmental resources. Such forms of transport are also relatively inconvenient in that the product must be moved batch wise, rather than continuously. In an attempt to address this problem, belt conveyors have been used. However, these have generally been found to be unreliable, impractical and financially non- viable over longer distances. They are also subject to environmental influences, and cannot be used to transport minerals over water, for example. As a possible alternative to such conventional methods, numerous attempts have been made to transport minerals in slurry form along pipe lines. However, this has proven to be problematic in practice. Particularly, in the case of dense ores, it has been found that excessively high pumping pressures are required. This adds to the size, number and cost of the pumps required, as well as to the cost of the pipe lines themselves which must be built to withstand the higher internal pressures. Even then, only relatively low pumping speeds can be achieved. It has also been found that conventional positive displacement type pumps are unreliable and prone to rapid wear in such applications, typically because the valve mechanisms cannot successfully accommodate large abrasive particles. Furthermore, it has been found that dense phase slurries moving along pipelines are particularly sensitive to vibration and pressure variations. Even relatively minor disturbances of this nature can de-stabilise the moving slurry bed within the pipe line, causing the dense particles to precipitate out of suspension from the carrier fluid, resulting in blockages which are difficult to locate and clear. For these reasons, the transportation of minerals by pipe line has, for the most part, proven to be commercially non-viable, particularly over longer distances where the greatest economic potential for this mode of transport resides. It is an object of the present invention to provide an improved method which overcomes or substantially ameliorates at least some of these disadvantages of the prior art. DISCLOSURE OF THE INVENTION Accordingly, in a first aspect, the invention as presently contemplated provides a method of transportation of mineral ores, said method comprising the steps of crushing the ore into relatively fine particles, mixing the crushed ore with a liquid carrier to form a relatively high density mineral slurry, injecting a gas to aerate the slurry and produce a relatively low density mineralised froth, and pumping the aerated slurry and froth along a fluid pipe line. Preferably, the method includes the further step of adding a flocculating agent to the slurry, thereby further reducing the density and stabilising the froth. Preferably also, a soluble lubricant is added to reduce viscosity and facilitate pumping. The method preferably comprises the further step of separating the desired minerals from the froth at the remote end of the pipe line. The separation process preferably includes one or more of: microwave heating; ultrasonic separation; cyclone separation; flotation; spraying; electrostatic precipitation; filtration; and drying. In one preferred embodiment, a return pipe line flows upstream from the separation station to a mixing station, whereby recovered flocculant, carrier liquid, and other additives are recirculated and re-used. In the preferred form of the invention, the pumping step is performed by a twin cylinder positive displacement type pump with off-set pumping chambers and floating unidirectional flap valves, thereby accommodating larger particles and producing a relatively pulse-free output. Alternatively, however, a continuous flow peristaltic type pump or other suitable pumps can also be used. According to a second aspect, the invention provides an apparatus for transportation of mineral ores, said apparatus comprising crushing means to crush the ore into relatively fine particles, mixing means to mix the crushed ore with a liquid carrier to form a relatively high density mineral slurry, injection means to inject a gas into the slurry thereby to aerate the slurry and produce a relatively low density mineralised froth, and pumping means to pump the aerated slurry and froth along a fluid pipe line. BRIEF DESCRIPTION OF THE DRAWINGS A preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:- Figure 1 is schematic view showing a long distance mineral transportation pipe line system including a pumping station according to the invention; Figure 2 is an enlarged diagrammatic plan view showing the pumping station of Figure 1; Figure 3 is a diagrammatic cross-sectional view taken along line 3-3 of Figure 2, showing the pump assemblies in more detail; Figure 4 is an enlarged longitudinal section showing one of the floating flap valves from the pumping station of Figure 2, with the valve in the closed position; Figure 5 is an enlarged sectional plan view of the flap valve of Figure 4; Figure 6 is a schematic view showing a typical hydraulic drive arrangement for the pump assembly of Figure 3; Figure 7 is an enlarged diagrammatic plan view showing an alternative arrangement to the pumping station of Figure 2; Figure 8 is a diagrammatic cross-sectional view taken along line 8-8 of Figure 7, showing the pump assemblies in more detail; and Figure 9 is a diagrammatic view showing the pumping station connected to a fluid pipe line according to the invention, illustrating graphically the typical pressure and velocity gradients. PREFERRED EMBODIMENTS OF THE INVENTION Referring firstly to Figure 1, the ore is initially processed, crushed and reduced to relatively fine particles in a conventional processing plant 1. The crushed ore is then fed to a belt conveyor 2 for transportation to a mixer 3. In the mixer, the crushed ore is mixed with a liquid carrier, which may be mine water for example, to form a relatively high density mineral slurry. The mixer includes programmable metering devices and feeders (not shown) for the crushed minerals, oxides or concentrates, the liquid carrier, flocculating agents, plasticisers, lubricants and other components required to optimise the pumping characteristics. The slurry is fed from the mixer 3 to a post-treatment station (not shown) where gas is injected to aerate the slurry and produce a mineral enriched froth having a relatively high degree of stability and relatively low density. The mineralised froth is then fed to a pumping station 5, which will be described in more detail below. A nucleonic flow monitoring device 5 A is positioned downstream of the pumping station to permit constant monitoring and control over output velocity, flow rate and density. The froth then flows into the main pipe line 6 for long distance transportation. The pipe line terminates at a separation station 7 from which the ore 8 is recovered. The separation station 7 is shown diagrammatically as a cyclone separator. It will be appreciated, however, that a number of separation processes such as cyclone separation, flotation, spraying, electrostatic precipitation, filtration and drying may be used in order to separate and concentrate the ore. The overflow from the separation station is directed to a recirculation unit 9, and thence recirculated through line 10 back to the mixer 3 whereby the recovered flocculant, carrier liquid, and other additives may be reused. Upon aeration upstream of the pumping station, the dense slurry forms the walls of a myriad of gas bubbles, which make up the mineralised froth. The size of the bubbles is directly related to the dry density of the mineral ore and the density of the resultant slurry. Ideally, the gas bubble and the surrounding slurry skin should result in a structure having an overall specific gravity or relative density of less than 1.0. Due to the dramatic change in density, the aerated slurry or froth has been found to be far more manageable in terms of its pumping characteristics. In particular, it can be pumped at higher velocities with considerably lower pressure requirements than would be required with untreated slurries. In turn, this results in fewer and smaller capacity pumps, reduced pipe line diameter, reduced pipe wall thickness, and in many cases enables the use of non-metallic pipes. Figure 2 shows a first embodiment of a pumping station 5 in more detail. It will be seen that between the inlet 1 1 and outlet 12, the pipe line divides into two branches, 6A and 6B. Each branch has an associated positive displacement pump cylinder 13 driven by a double acting hydraulic actuator 14, and a pair of unidirectional floating flap valves 15 and 16. The cylinders and actuators 13 and 14 are shown in more detail in Figure 3, whilst the flap valves are shown in Figures 4 and 5. Referring to Figures 2 to 5, it will be seen that as each pump cylinder 13 is displaced downwardly by its actuator 14, the resultant pressure rise in the associated branch of the pipe line causes the upstream flap valve 15 to close and the downstream valve 16 to open, thereby forcing fluid through the outlet 12. The effect of this pumping phase is shown with dark shading in branch line 6A. As each cylinder is subsequently withdrawn, the resultant negative pressure in the associated branch line causes the downstream flap valve 16 to close and the upstream valve 15 to open. The suction pressure then draws fresh fluid into the branch line through the inlet 11. The effect of this suction phase is shown with dark shading in branch line 6B. With the pump cylinders 13A and 13B operating 180° out of phase, a substantially continuous flow is maintained. Moreover, because the flap valves are free-floating, they are able to accommodate relatively large particulates without the risk of mechanical failure and with minimal abrasive wear. A typical hydraulic drive arrangement for the pump actuators 14 is shown in Figure 6, whereby a single control valve 18 is used alternately to direct driving fluid into the pressure chambers of each actuating cylinder. It will be appreciated, however, that -. 1 - alternative hydraulic, electrical or mechanical drive mechanisms may also be used, as may a variety of different pumps. Figures 7 and 8 show a second embodiment of the pumping station 5 wherein, corresponding features are denoted by corresponding reference numerals. In this case, again, it will be seen that between the inlet and outlet, the pipe line divides into two branches, 6 A and 6B. Each branch has an associated diaphragm type pump assembly 20, as best seen in Figure 8. Each diaphragm pump includes a flexible diaphragm 21 movable within a pumping chamber 22 by means of an hydraulic actuator or mechanical driver 23. As with the previous embodiment, each pump acts in conjunction with a pair of unidirectional floating flap valves 15 A, 15B, 16A and 16B, or other suitable alternatives such as polyurethane ball valves, or gas or liquid operated pinch valves (not shown). The hydraulic drive arrangement for the pump actuator, of the type shown in Figure 6, is also suitable for use with the actuators 23 associated with the diaphragm type pump arrangement shown in Figures 7 and 8. Figure 9 shows a diagrammatic view of the pumping station 5 connected to a fluid pipe line 6. Due to the stored energy contained in the compressed gas bubbles constituting the froth, the media will travel in the pipe line form an initially compressed state at the pump outlet, through a progressively decompressed state toward the pipe line outlet. Consequently, the flow velocity at the inlet to the pipe line will be substantially less than the delivery velocity at the outlet point. Typically, the velocity may vary from 0.05 metres per second at the inlet to more than 3 metres per second at the discharge point of the pipe line. It will be appreciated, however, that the actual flow velocities will be dependent upon a number of variables such as the volumetric flow rate and the pressure capacity of the pump, the length and diameter of the pipe line, the nature of the materials being pumped, the concentration of froth, and the like. In Figure 9, the progressively increasing velocity gradient of the fluid is illustrated by the graphical representation V f , whereas the typical progressively reducing pressure profile is represented graphically as P f ' the parameter in each case being plotted against distance along the pipe line. Again, however, it will be emphasised that the actual pressure and velocity profiles will be subject to a number of variables and may not necessarily be linear. It will also be noted that the rate at which material is drawn into each pump during the suction stroke will be relatively constant, whereas the volume of fluid injected into the pipe line during each compression stroke will vary, according to the pressure and load status of the pipe line. Thus, as back pressure increases in the pipe line, a correspondingly smaller volume of more highly compressed fluid will be injected during each compression stroke. In this way, the pipe line acts a self-regulating damper, distributing pressure relatively uniformly from the inlet end toward the open outlet. As the length of the pipe line increases, its pressure characteristics resemble an open ended gas spring, with only transient back pressure at the outlet of the pump. The present invention enables dense mineral ores to be transported by pipe line over relatively long distances at higher velocities, with lower pressures and with better reliability than have previously been achievable with dense phase slurries. This not only increases transport range and throughput, but at the same time reduces the capital cost of the pumps and pipe lines. The invention also allows a significant reduction in water consumption, whilst power consumption is also significantly reduced. Further advantages include a reduction in capitalisation cost, a reduction in operating cost, and substantially reduced exposure of the ore to contamination by environmental and other influences. The - α - invention thus considerably enhances the commercial viability of long distance mineral transportation by pipe line, and thereby represents a significant improvement over the prior art. Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Claims: CLAIMS:- 1. A method of transportation of mineral ores, said method comprising the steps of crushing the ore into relatively fine particles, mixing the crushed ore with a liquid carrier to form a relatively high density mineral slurry, injecting a gas to aerate the slurry and produce a relatively low density mineralised froth, and pumping the aerated slurry and froth along a fluid pipe line. 2. A method according to claim 1 , including the further step of adding a flocculating agent to the slurry, thereby further reducing density and stabilising the froth. 3. A method according to claim 1 or claim 2, including the further step of adding a soluble lubricant to reduce viscosity and facilitate pumping. 4. A method according to any one of claims 1 to 3, including the further step of separating the desired minerals from the froth at a remote end of the pipe line. 5. A method according to claim 4, wherein the separation step includes one or more of the following processes:- (a) microwave heating; (b) ultrasonic separation; (c) cyclone separation; (d) flotation; (e) spraying; (f) electrostatic precipitation; (g) filtration; or (h) drying. 6. A method according to any one of the preceding claims, including the further step of recovering flocculant, carrier liquid, or other additives for recirculation upstream from a separation station to a mixing station via a return pipe line, whereby recovered materials are reused. 7. A method according to any one of the preceding claims, wherein the pumping step is performed by means of a twin cylinder positive displacement type pump with offset pumping chambers and floating unidirectional flap valves, said pump being adapted to accommodate larger particles and to produce a relatively pulse free output. 8. A method according to any one of claims 1 to 6, wherein the pumping step is performed by means of a continuous flow peristaltic type pump. 9. A method according to any one of the preceding claims, including the further step of monitoring a velocity, flow rate or density parameter downstream of the pumping station, and regulating the pumping process in response to the monitored parameter with reference to a predetermined set point. 10. An apparatus for transportation of mineral ores, said apparatus comprising crushing means to crush the ore into relatively fine particles, mixing means to mix the crushed ore with a liquid carrier to form a relatively high density mineral slurry, injection means to inject a gas into the slurry thereby to aerate the slurry and produce a relatively low density mineralised froth, and pumping means to pump the aerated slurry and froth along a fluid pipe line. 1 1. An apparatus according to claim 10, wherein the mixing means is further adapted to add a flocculating agent to the slurry, thereby further reducing density and stabilising the froth. 12. An apparatus according to claim 10 or claim 11 , wherein the mixing means are further adapted to add a soluble lubricant to reduce viscosity and facilitate pumping of the aerated slurry and froth. 13. An apparatus according to any one of claims 10 to 12, further including separation means adapted to separate the desired minerals from the froth at a remote end of the fluid pipe line. 14. An apparatus according to any one of claims 10 to 13, further including recirculation means adapted to recover flocculant, carrier liquid or other additives, for recirculation upstream from a separation station to a mixing station via a return pipe line, whereby recovered materials are re-used. 15. An apparatus according to any one of claims 10 to 14, wherein said pumping means comprise a twin cylinder positive displacement type pump with off-set pumping chambers and floating unidirectional flap valves, said pump being thereby adapted to accommodate relatively large particles and to produce a relatively pulse free output. 16. An apparatus according to any one of claims 10 to 14, wherein said pumping means comprise a continuous flow peristaltic type pump. 17. An apparatus according to any one of claims 10 to 16, further including monitoring means adapted to monitor a velocity, flow rate or density parameter downstream of the pumping means, and control means adapted to regulate the pumping process in response to variations in the monitored parameter with reference to a predetermined set point. 18. A method of transporting mineral ores, substantially as hereinbefore described with reference to the accompanying drawings. 19. An apparatus for transportation of mineral ores, substantially as hereinbefore described with reference to the accompanying drawings.

Inventors: BERTONY JOSEPH, BERTONY, JOSEPH
Applicants: BERTONY JOSEPH, PUMPING SYSTEMS TECHNOLOGIES P, BERTONY, JOSEPH, PUMPING SYSTEMS TECHNOLOGIES PTY. LIMITED
Application year: 1997
Main classification: B65G53
IPC codes: B65G53, F04B15