Velocity Profile Bitumen Detection in Coarse Tailings Lines
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Solution Overview
Problem
In the coarse tailings line of oilsands separation plants, there is no effective method to accurately determine the amount of bitumen present, leading to inefficiencies in capturing bitumen and excessive water discharge, resulting in both environmental hazards and loss of valuable hydrocarbon content.
Innovation Solution
A signal processor system that uses a velocity profile meter to detect the presence of bitumen in the process flow, providing signaling to control a diverter or skimmer to optimize bitumen capture and minimize water discharge, allowing for real-time adjustment of diversion based on fluid flow velocity profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a fixed diverter plate is used to skim bitumen from the tailings line, then bitumen capture is achieved, but water is excessively captured and bitumen recovery is inefficient due to inability to adjust to varying bitumen concentrations
Solution Approach 1:
The patent replaces the fixed diverter plate with a movable diverter plate whose position can be dynamically adjusted based on real-time bitumen concentration measurements. The diverter plate position is controlled by a actuator system that responds to signals from sensors detecting bitumen presence and concentration, allowing the system to adapt to varying flow conditions and optimize the balance between bitumen capture and water discharge.
Solution Approach 2:
The system incorporates sensors (such as velocity profile meters or optical sensors) that continuously monitor bitumen concentration in the tailings line and provide feedback signals to the control system. This feedback loop enables automatic adjustment of the diverter plate position to maintain optimal bitumen recovery while minimizing water discharge, directly addressing the inefficiency of fixed diverter systems.
2Productivity
If pumping is used to transport tailings, then transport efficiency is improved, but additional conditioning occurs that causes bitumen separation and floating, making detection and capture difficult
Solution Approach 1:
The system performs preliminary detection of bitumen concentration and distribution in the pumped tailings flow using sensors positioned in the tailings line. By detecting bitumen presence and velocity profile changes before the tailings reach the tailings pond, the system can proactively adjust the diverter plate position to capture separated bitumen, addressing the detection difficulty created by pumping-induced separation.
3Loss of substance
If no measurement system is used, then device complexity is reduced, but bitumen presence and concentration cannot be determined, leading to suboptimal capture efficiency
Solution Approach 1:
The patent employs non-mechanical sensing methods such as velocity profile measurement using acoustic or electromagnetic sensors, or optical detection methods, to measure bitumen concentration and flow characteristics. These field-based measurement techniques replace complex mechanical sampling and analysis systems, providing accurate bitumen detection with relatively simple sensor installations and electronic signal processing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables precise determination and capture of bitumen, reducing its discharge to the tailings pond and maximizing recovery, thereby addressing the inefficiencies in existing methods and minimizing environmental impact.
Implementation Method 1
The velocity profile meter may be a wrap-around velocity profile meter that uses multiple sensing arrays, including where the multiple sensing arrays are located radially at a top position of 0°, a bottom position of 180°, and intermediate positions 45°, 90° and 135°.
Data Source
AI summary
The present invention provides techniques for recovering hydrocarbon fluids in a process flow, including recovering bitumen from a coarse tailings line. The apparatus includes a signal processor that responds to signaling containing information about the presence of a hydrocarbon fluid in a process flow; and determines corresponding signaling to control the diversion of the hydrocarbon fluid from the process flow remaining based on the signaling received. The hydrocarbon fluid may be bitumen, including bitumen flowing in a course tailings line. The signal processor receives the signaling from a velocity profile meter having sensors arranged around a circumference of a process pipe containing information about a fluid flow velocity at various levels or heights within the process pipe, including a wrap-around velocity profile meter having multiple sensing arrays located radially at a top position of 0°, a bottom position of 180°, and intermediate positions 45°, 90° and 135°.