Tailings Recovery Hollow Shell Density Control

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Solution Overview

Problem

Existing systems for managing tailings ponds face challenges such as pump clogging due to debris, viscosity issues leading to pump coning, and varying rheological properties of fine fluid and mature fine tailings, which disrupt the steady supply of fines with desired density, affecting treatment process efficiency and compliance with regulations.

Innovation Solution

A system involving a hollow shell positioned within the tailings pond with strategically located holes to control the flow of fine tailings, using internal and external water delivery to maintain desired density, and chemical addition to prevent coning and ensure steady flow, balancing hydraulic pressures and shear resistance for efficient recovery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If submersible pumps are installed in the tailings pond to pump out fines, then fines can be collected and processed, but the pump suction becomes clogged due to debris and muskeg, requiring pump removal for cleaning

Engineering Contradiction:

Improvefines collection rateVSAvoidpump operation continuity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The pump system is divided into an above-water pump unit and a submerged intake structure. The pump itself remains above water on a barge, while only the intake components are submerged, allowing easy access for maintenance without removing the entire pump system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A screen or filter structure is introduced as an intermediary between the tailings pond and the pump intake. This screen prevents debris and muskeg from entering the pump suction while allowing fines to pass through, eliminating clogging issues.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If submersible pumps are used to pump fines, then fines can be recovered, but pump coning occurs due to viscosity differences, preventing desired density fines from entering the pump

Engineering Contradiction:

Improvefines recovery efficiencyVSAvoidfines density control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The intake structure is designed to extend vertically through different density layers, with multiple intake openings at different depths. This allows the system to draw from multiple density zones simultaneously, achieving a balanced, steady-density feed to the pump and preventing coning.

Inventive Principle:

Principle #12Equipotentiality

Solution Approach 2:

The intake structure transitions from a single-point suction to a distributed vertical array of intake openings. This dimensional change from point to line intake allows sampling across the density gradient without creating coning disturbances.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Quantity of substance

If pumps are installed at different depths to target specific fines layers, then different density fines can be accessed, but clear water is drawn instead of target fines, forming an upward cone

Engineering Contradiction:

Improvetarget density fines supplyVSAvoidfines density specification

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

Multiple intake openings at different depths are combined into a single integrated intake structure. This merges the flow from different density zones into a unified flow that maintains target density specifications while preventing water coning through proper geometric design.

Inventive Principle:

Principle #5Merging (Combining)

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

The system prevents upward and downward coning, ensuring a steady flow of fines with desired density, maintaining process efficiency and compliance with regulations by controlling the flow and density of fine tailings, thereby improving the management of tailings ponds.

Implementation Method 1

The number, the shape, and the size of each hole is selected such that when fine tailings are being removed from within the shell, a net hydraulic head pressure acting upon the fine tailings at an exterior side of the shell balances a sum of a net hydraulic head pressure acting over a predetermined fill level height upon the fine tailings at an interior side of the shell, a dynamic pressure of the fine tailings, and an operating shear resistance of the fine tailings

Methodology Applied

Scientific EffectHydrostatic pressure: Pressure Gradient

Implementation Method 2

fine fluid tailings and mature fine tailings are known to have non-Newtonian, Bingham plastic, rheological properties represented by yield stress and plastic viscosity

Methodology Applied

Scientific EffectBingham plastic flow: Bingham Plastic

Data Source

PatentUS10864464B2Tailings recovery system

Publication Date: 2020.12.15 GOMAA ALY

AI summary

A method for recovering fine tailings from a tailings pond includes selecting a desired density of fine tailings to be removed from the tailings pond. Positioning a hollow shell having a closed bottom and holes formed through a sidewall of the shell within the tailings pond such that the holes are located at a depth of a layer of the fine tailings of the desired density and such that a top of the shell is disposed above a free water surface of the pond. Causing a flow of the fine tailings of the desired density through the holes into into the shell and removing the fine tailings of the desired density from within the shell.