Tailings and Mine Waste 2009

Paste Pumping and Deposition Field Trials and Concepts on Syncrudes Dewatered Mature Fine Tailings (MFT) (Centrifuge Cake)
Rick Lahaie Syncrude Canada Ltd. Isaac Ahmed, Mark Labelle, Rob Brown Golder Paste Technology Ltd.

Outline Bench Scale to Pilot Testing

Brief introduction to MFT centrifuge process All testwork was completed at Syncrudes Mildred Lake Operation Two phase approach, with the objective determine pumpability of MFT centrifuge cake (paste) Bench scale rheological examination of centrifuge cake at 50 to 60 wt.% solids Design field testing (flow loop) of a positive displacement pumping system for the centrifuge cake Preliminary deposition concepts

Scope of MFT Centrifuge Field Trials

MiSwaco

Two pods of oilfield scale centrifuges were operated in parallel by Syncrude Two Alfa Laval Lynx 40s running in parallel with the prime focus provide centrifuge cake for:

Alfa Laval

Transportation assessment conveyor and positive displacement pump / pipeline studies (Golder PasteTec) Bulk materials for geotechnical and environmental studies

Single MiSwaco 518 centrifuge used to Advance MFT flocculation and MFT centrifuge process understanding:

Flocculant optimization studies Centrifuge operational parameter assessments

Overview MFT Centrifuge Pilot Plant Set-up

Golder Paste Tec Set-Up Stacker

Centrifuge Cake Deposits

Centrifuges

Flocculant Storage/Mixing MFT Storage Tanks

Interim MFT Supply Pond

Bench Scale Phase I

Determine if MFT centrifuge cake can be pumped First phase bench scale rheology testing MFT centrifuge cake: 50 to 60 wt.% solids Centrate to less than 1 wt.% solids High flocculant content, 1300 g/tonne Low slump values, less than 5 Results show High yield stress, ranging from 600 to 1200 Pa Metal mine pastes have yield stresses of about 200 Pa High yield stress ~attributed to high flocculant dosage. Metal mine pastes, 20 to 50 g/tonne

Bench Scale Phase I

1400 1200 9/12/2008 4:00 PM Standard 9/12/2008 4:00 PM Sheared

Yield Stress (Pa)

1000 800 600 400 200 0 0%

20% 40% 60% Solids Content (w t%)

80%

Sampling of MFT centrifuge cake Target conditions Upset conditions Sheared / unsheared Yield stress values gives some indication on ease of pumping To pump MFT centrifuge cake material must be sheared first By shearing the sample the yield stress can be reduced significantly

Field Pumping Phase II Equipment Set-Up

Overall Set-Up

Piping & Instrumentation

Field equipment was set-up to pump the MFT centrifuge cake Data captured is used to determine pipeline friction loss MFT centrifuge cake pumping process Material discharged from the stacker enters the paste / hopper truck The truck shears and discharges into the pump truck Material is pumped via piston pump to a deposition cell Pressure sensors and flow meter are used to capture data in real time for interpretation under different conditions

Field Pumping Phase II Equipment Set-Up

Centrifuge Cake Discharge
Pipe Discharge Pressure Transducer #1 Flowmeter
615 cm

Hopper Truck
100 mm

Pressure Transducer #2

790 cm

ANSI Flange

2805 cm

Pumper Truck
3412 cm

Shearing with screw auger and mixer

915 cm

Reducer Pipes

Pipe Clamps

Field Pumping Phase II Data Acquisition

1000 900 800 700

Pressure (kPa)

3.0

2.5

2.0
Flow (m/sec)

600 500 400 300 200 100 0 0 10 20 30

Time (sec)

1.5

1.0

0.5

0.0 40 50 60

Pressure differential and flow-rate Pump strokes can be readily observed on graph Dataset is analysed and follows the Bingham plastic model MFT centrifuge cake has characteristics of paste

Transducer 1 (kPa)

Transducer 2(kPa)

FM (m/sec)

Field Pumping Phase II Data Analysis

80

Test 3
70

Test 4

Test 5

60 50 40 30 20 10 0 0.00

0.50

1.00

1.50

2.00

2.50

Flow Velocity (m/sec)

First step is to determine relationship between pressure loss and flow rate The raw data collected (previous slide) represents one point on each curve A series of runs at different flow-rates at the same material consistency represents one test

Pressure Losses (kPa / m)

Field Pumping Phase II Pipe Friction Factors

10 9 8 Test 3 Test 4

Pressure Loss, (kPa/m)

7 6 5 4 3 2 1 0 0.00

Using the Bingham Plastic model, pipe friction factors can be obtained Data presented is scaled up to 350 mm diameter schedule 40 pipe from field set-up of 40 mm diameter pipe

0.25

0.50

0.75

1.00

1.25

1.50

1.75

2.00

Flow Velocity (m/sec)

Field Pumping Phase II Transport & Deposition

MFT centrifuged cake (paste) was pumped and deposited 10 kPa/m for 8 pipe diameter (200 mm) 5 kPa/m for a 14 pipe diameter (350 mm) Values presented are for 1 m/s flow velocity Natural deposition angle was apparent

Mixer Discharge (Click to Start)

Pipe Discharge (Click to Start)

Deposition (Click to Start)

Deposition Concepts

Subsequent dewatering of the cake by natural processes; consolidation, desiccation and freeze thaw via either / or:

1 to 2 m annual layers or lifts, delivering a trafficable surface that can be reclaimed terrestrially; A very thick, potentially 30 m layer deposited in the mined out pits where, with time, consolidation further dewaters the cake to deliver a deposit that can be reclaimed terrestrially or by water capping.

Conclusion

MFT centrifuge cake can be pumped, but it must be sheared first reduce yield stress MFT centrifuge cake like paste can be characterized (rheology) using the Bingham Plastic model Pipeline friction factors are relatively high but can be pumped via positive displacement pumps When deposited the material showed little water bleed - an advancing front is apparent with surface cracking Syncrude is currently investigating all cake transport alternatives - trucking with specialty boxes, pumping, conveying and possibly direct deposit from floating centrifuge barges for some in-pit deposition.

Tailings and Mine Waste 2009

Thank you! Questions / Comments

Rick Lahaie Syncrude Canada Ltd. Isaac Ahmed, Mark Labelle, Rob Brown Golder Paste Technology Ltd.