dr steve algie - flocep - manipulating the nature of slurry flows to overcome production &...
DESCRIPTION
The 4th Annual Slurry Pipelines Conference is the world's only event wholly dedicated to the operational challenges, design questions, innovations, pumps and tailings related to slurry pipelines in the mining and resources sectors. For more information on the event, please visit: http://bit.ly/1xvoBPTTRANSCRIPT
Manipulating the nature of slurry flows to overcome production and maintenance challenges
DR STEVE ALGIE CONSULTANT, FLOCEP PTY LTD
1
What is PROmotion™ Technology? PROmo&on Technology is the basis for:
• a family of devices that
• solve problems arising from the inherent tendency for
• segrega&on of the solids within slurry flows
2
Engineering models (usefully) simplify reality
3
Newitt’s slurry flow classification (single particle size)
4
Fully suspended
Suspended with moving bed
Suspended with salta?on (par?cles ‘hop’ along pipe)
Blocked pipe Len?cular deposits
Sta?onary deposits with ripples In
creasin
g velocity
Increasing solids concentra?on
FLOprep unit
5
• Flow prepara?on upstream of hydrocyclone distributor
• Solids loading ≈60%; high abrasion index (47)
• FLOprep installed 2012 • Projected life 188 weeks
• Flow rate changes have not affected performance
• Accepted and performance validated by client
Evolu&on Mining -‐ Edna May Opera&ons
FLOdistributor
6
Evolu&on Mining -‐ Edna May Opera&ons
During installa&on in a scheduled 12-‐hour shut-‐down
In use
FLOdistributor
7
Evolu&on Mining -‐ Edna May Opera&ons
• Gold recovery increased from ≈90% to ≈ 94%
• Stable performance allows op&mal process opera&ons
• Maintenance costs reduced 95% • uniform wear on cyclones
• Underflow densi&es uniform to 1% solids (74-‐75%) • Maintenance intervals increased from 3 days to 4 months • Cyclone life cycle increased from 3 weeks to 4 months • Rubber-‐lined spools not replaced in more than two years’ opera&on (previous ceramic spools had 16 week life)
MAXbend®
8
The situa?on: • Most severe loca?on in the plant for bend wear
• Superheated caus?c slurry entering first flash tank
• Flashing inside bend results in very high erosion
• Standard bend life 120 days
Alumina refinery in southwest WA
MAXbend® performance
9
• MAXbend® installed in alumina refinery in 2012 • service to date ≈900 days
• Projected life:1800 days (15 &mes mul&plier) • Accommodated a flow rate increase of ≈20% with no effect on MAXbend® performance
• Acceptance and validated performance by both clients • Rental op?on offered to clients and under considera?on
Similarly spectacular results in Sandfire Resources’ DeGrussa copper-‐gold opera&ons
10
MAXbend® Performance Timeline
Standard Bend Life MAXbend® Bend Life
Note : Expected life based on inspec&on results from 1 year’s service (April 2013) and 2 year’s service (June 2014)
A PROmo&on™ Technology
Where might you use PROmotion™ Technology? PROmo?on™ Technology pays off in places where the non-‐homogeneous flow inside the pipe might get you into trouble: • Measurement, or sampling • Addi?on of a chemical • Spliang a slurry flow • Where there’s a bend in the pipe
Consider how much easier these opera&ons would be if the slurry were actually homogeneous at these points!
Then …
11
Think of PROmotion™ Technology! FloCEP informa?on contacts:
www.flocep.com.au (under construc?on)
Phone: +61 8 9353 3929
Author contacts:
Dr Steve Algie
algie@mul&line.com.au
Phone: +61 8 9385 9969
12