CA2733873A1 - Device and method for screening pre-treatment of oil sands tailings - Google Patents
Device and method for screening pre-treatment of oil sands tailings Download PDFInfo
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- CA2733873A1 CA2733873A1 CA 2733873 CA2733873A CA2733873A1 CA 2733873 A1 CA2733873 A1 CA 2733873A1 CA 2733873 CA2733873 CA 2733873 CA 2733873 A CA2733873 A CA 2733873A CA 2733873 A1 CA2733873 A1 CA 2733873A1
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- screening
- screening device
- screen
- fluid flow
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- 238000012216 screening Methods 0.000 title claims abstract description 285
- 238000000034 method Methods 0.000 title claims abstract description 42
- 238000002203 pretreatment Methods 0.000 title description 2
- 239000012530 fluid Substances 0.000 claims abstract description 112
- 238000011282 treatment Methods 0.000 claims abstract description 26
- 239000000126 substance Substances 0.000 claims abstract description 21
- 239000000463 material Substances 0.000 claims abstract description 19
- 238000004140 cleaning Methods 0.000 claims description 10
- 238000007689 inspection Methods 0.000 claims description 8
- 238000011144 upstream manufacturing Methods 0.000 claims description 4
- 238000007599 discharging Methods 0.000 claims description 3
- 238000005189 flocculation Methods 0.000 claims description 3
- 230000016615 flocculation Effects 0.000 claims description 3
- 230000002787 reinforcement Effects 0.000 claims description 3
- 238000012423 maintenance Methods 0.000 claims description 2
- 238000001514 detection method Methods 0.000 claims 1
- 238000005086 pumping Methods 0.000 claims 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 15
- 239000011707 mineral Substances 0.000 description 15
- 229930195733 hydrocarbon Natural products 0.000 description 11
- 150000002430 hydrocarbons Chemical class 0.000 description 11
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 10
- 239000002245 particle Substances 0.000 description 9
- 239000004215 Carbon black (E152) Substances 0.000 description 7
- 238000000605 extraction Methods 0.000 description 7
- 239000003027 oil sand Substances 0.000 description 7
- 239000007787 solid Substances 0.000 description 7
- 230000008569 process Effects 0.000 description 6
- 239000004576 sand Substances 0.000 description 5
- 239000004927 clay Substances 0.000 description 3
- 238000007726 management method Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 238000009825 accumulation Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000011010 flushing procedure Methods 0.000 description 2
- 230000014509 gene expression Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012544 monitoring process Methods 0.000 description 2
- 241000237858 Gastropoda Species 0.000 description 1
- 239000010426 asphalt Substances 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 238000007596 consolidation process Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
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- 238000000926 separation method Methods 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
- B01D29/01—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with flat filtering elements
- B01D29/03—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with flat filtering elements self-supporting
Abstract
The present invention provides a device for screening debris from an oil sands tailings fluid flow coming from an inlet line to pre-treat the oil sands tailings fluid flow for chemical treatment. The screening device comprises a screen having a screening surface being configured to allow material with a predetermined size to flow through the screening surface and separate coarse debris. The device also comprises a collector body having side walls extending from the screening surface and configured to receive a screened fluid flow for the chemical treatment. The present invention further provides a method for screening debris from an oil sands tailings fluid flow coming from an inlet line to pre-treat the oil sands tailings fluid flow for chemical treatment.
Description
DEVICE AND METHOD FOR SCREENING PRE-TREATMENT OF OIL SANDS
TAILINGS
FIELD OF THE INVENTION
The invention generally relates to the field of oil sands tailings treatment.
More precisely, it provides a device and a related method for screening coarse debris from oil sands tailings prior to the chemical treatment of these tailings.
BACKGROUND
Oil sand tailings are generated from hydrocarbon extraction process operations that separate the valuable hydrocarbons from oil sand ore. All commercial hydrocarbon extraction processes use variations of the Clark Hot Water Process in which water is added to the oil sands to enable the separation of the valuable hydrocarbon fraction from the oil sand minerals. The process water also acts as a carrier fluid for the mineral fraction. Once the hydrocarbon fraction is recovered, the residual water, unrecovered hydrocarbons and minerals are generally referred to as "tailings".
The oil sand industry has adopted a convention with respect to mineral particle sizing.
Mineral fractions with a particle diameter greater than 44 microns are referred to as "sand". Mineral fractions with a particle diameter less than 44 microns are referred to as "fines". Mineral fractions with a particle diameter less than 2 microns are generally referred to as "clay", but in some instances "clay" may refer to the actual particle mineralogy. The relationship between sand and fines in tailings reflects the variation in the oil sand ore make-up, the chemistry of the process water and the extraction process.
Conventionally, tailings are transported to a deposition site generally referred to as a "tailings pond" located close to the oil sands mining and extraction facilities to facilitate pipeline transportation, discharging and management of the tailings. Due to the scale of operations, oil sand tailings ponds cover vast tracts of land and must be constructed and managed in accordance with regulations. The management of pond location, filling, level control and reclamation is a complex undertaking given the geographical, technical, regulatory and economic constraints of oil sands operations.
Each tailings pond is contained within a dyke structure generally constructed by placing the sand fraction of the tailings within cells or on beaches. The process water, unrecovered hydrocarbons, together with sand and fine minerals not trapped in the dyke structure flow into the tailings pond. Tailings streams initially discharged into the ponds may have fairly low densities and solids contents, for instance around 0.5-10 wt%.
In the tailings pond, the process water, unrecovered hydrocarbons and minerals settle naturally to form different strata. The upper stratum is primarily water that may be recycled as process water to the extraction process. The lower stratum contains settled residual hydrocarbon and minerals which are predominately fines. This lower stratum is often referred to as "mature fine tailings" (MFT). Mature fine tailings have very slow consolidation rates and represent a major challenge to tailings management in the oil sands industry.
The composition of mature fine tailings is highly variable. Near the top of the stratum the mineral content is about 10 wt% and through time consolidates up to 50 wt% at the bottom of the stratum. Overall, mature fine tailings have an average mineral content of about 30 wt%. While fines are the dominant particle size fraction in the mineral content, the sand content may be 15 wt % of the solids and the clay content may be up to 75 wt%
of the solids, reflecting the oil sand ore and extraction process. Additional variation may result from the residual hydrocarbon which may be dispersed in the mineral or may segregate into mat layers of hydrocarbon. The mature fine tailings in a pond not only has a wide variation of compositions distributed from top to bottom of the pond but there may also be pockets of different compositions at random locations throughout the pond.
In response to economic and environmental concerns, mature fine tailings need to be dewatered and solidified through chemical treatments. In order to optimize these chemical treatments, mature fine tailings need to be screened in order to remove solid particles with a large particle size.
TAILINGS
FIELD OF THE INVENTION
The invention generally relates to the field of oil sands tailings treatment.
More precisely, it provides a device and a related method for screening coarse debris from oil sands tailings prior to the chemical treatment of these tailings.
BACKGROUND
Oil sand tailings are generated from hydrocarbon extraction process operations that separate the valuable hydrocarbons from oil sand ore. All commercial hydrocarbon extraction processes use variations of the Clark Hot Water Process in which water is added to the oil sands to enable the separation of the valuable hydrocarbon fraction from the oil sand minerals. The process water also acts as a carrier fluid for the mineral fraction. Once the hydrocarbon fraction is recovered, the residual water, unrecovered hydrocarbons and minerals are generally referred to as "tailings".
The oil sand industry has adopted a convention with respect to mineral particle sizing.
Mineral fractions with a particle diameter greater than 44 microns are referred to as "sand". Mineral fractions with a particle diameter less than 44 microns are referred to as "fines". Mineral fractions with a particle diameter less than 2 microns are generally referred to as "clay", but in some instances "clay" may refer to the actual particle mineralogy. The relationship between sand and fines in tailings reflects the variation in the oil sand ore make-up, the chemistry of the process water and the extraction process.
Conventionally, tailings are transported to a deposition site generally referred to as a "tailings pond" located close to the oil sands mining and extraction facilities to facilitate pipeline transportation, discharging and management of the tailings. Due to the scale of operations, oil sand tailings ponds cover vast tracts of land and must be constructed and managed in accordance with regulations. The management of pond location, filling, level control and reclamation is a complex undertaking given the geographical, technical, regulatory and economic constraints of oil sands operations.
Each tailings pond is contained within a dyke structure generally constructed by placing the sand fraction of the tailings within cells or on beaches. The process water, unrecovered hydrocarbons, together with sand and fine minerals not trapped in the dyke structure flow into the tailings pond. Tailings streams initially discharged into the ponds may have fairly low densities and solids contents, for instance around 0.5-10 wt%.
In the tailings pond, the process water, unrecovered hydrocarbons and minerals settle naturally to form different strata. The upper stratum is primarily water that may be recycled as process water to the extraction process. The lower stratum contains settled residual hydrocarbon and minerals which are predominately fines. This lower stratum is often referred to as "mature fine tailings" (MFT). Mature fine tailings have very slow consolidation rates and represent a major challenge to tailings management in the oil sands industry.
The composition of mature fine tailings is highly variable. Near the top of the stratum the mineral content is about 10 wt% and through time consolidates up to 50 wt% at the bottom of the stratum. Overall, mature fine tailings have an average mineral content of about 30 wt%. While fines are the dominant particle size fraction in the mineral content, the sand content may be 15 wt % of the solids and the clay content may be up to 75 wt%
of the solids, reflecting the oil sand ore and extraction process. Additional variation may result from the residual hydrocarbon which may be dispersed in the mineral or may segregate into mat layers of hydrocarbon. The mature fine tailings in a pond not only has a wide variation of compositions distributed from top to bottom of the pond but there may also be pockets of different compositions at random locations throughout the pond.
In response to economic and environmental concerns, mature fine tailings need to be dewatered and solidified through chemical treatments. In order to optimize these chemical treatments, mature fine tailings need to be screened in order to remove solid particles with a large particle size.
Several devices are used to remove large solid particles from oil sands tailings, such as basket filters or other conventional screening devices. Prior art devices typically require frequent cleaning and constant monitoring. Back flushing may also be needed.
Therefore, cleaning and back flushing activities lead to unplanned downtimes for the screening system.
In light of the aforementioned, there is a need for a new device and method which would be able to overcome at least some of the above-discussed drawbacks by providing a solution preventing less solid debris from plugging while requiring little to no additional maintenance or operations support.
SUMMARY OF THE INVENTION
The present invention responds to the above-mentioned need by providing a screening device and a method for screening coarse debris from oil sands tailings which is an improvement over known devices and/or methods.
More precisely, the present invention provides a screening device for screening debris from an oil sands tailings fluid flow coming from an inlet line to pre-treat the oil sands tailings fluid flow for chemical treatment. The screening device comprises a screen having a screening surface being configured to allow material with a predetermined size to flow through the screening surface and separate coarse debris, thereby splitting the tailings fluid flow into coarse debris and a screened fluid flow. The screening device also comprises a collector body having side walls extending from the screening surface and configured to receive the screened fluid flow for the chemical treatment.
According to one aspect of the screening device, the screening device may be particularly suitable for mature fine tailings that need to be further dewatered and dried.
According to another aspect of the screening device, the screen may comprise a plurality of screening bars. The screening bars may be parallel to one another and spaced apart from each other so as to define openings on either side of each bar, the openings being sized and shaped for only allowing the material of the predetermined size to flow through the screen towards the collector body.
Therefore, cleaning and back flushing activities lead to unplanned downtimes for the screening system.
In light of the aforementioned, there is a need for a new device and method which would be able to overcome at least some of the above-discussed drawbacks by providing a solution preventing less solid debris from plugging while requiring little to no additional maintenance or operations support.
SUMMARY OF THE INVENTION
The present invention responds to the above-mentioned need by providing a screening device and a method for screening coarse debris from oil sands tailings which is an improvement over known devices and/or methods.
More precisely, the present invention provides a screening device for screening debris from an oil sands tailings fluid flow coming from an inlet line to pre-treat the oil sands tailings fluid flow for chemical treatment. The screening device comprises a screen having a screening surface being configured to allow material with a predetermined size to flow through the screening surface and separate coarse debris, thereby splitting the tailings fluid flow into coarse debris and a screened fluid flow. The screening device also comprises a collector body having side walls extending from the screening surface and configured to receive the screened fluid flow for the chemical treatment.
According to one aspect of the screening device, the screening device may be particularly suitable for mature fine tailings that need to be further dewatered and dried.
According to another aspect of the screening device, the screen may comprise a plurality of screening bars. The screening bars may be parallel to one another and spaced apart from each other so as to define openings on either side of each bar, the openings being sized and shaped for only allowing the material of the predetermined size to flow through the screen towards the collector body.
According to another aspect of the screening device, the screening bars may have a flow-facing surface and side surfaces extending from the flow-facing surface with a relieving angle for avoiding plugging of the screening surface with the coarse debris.
According to another aspect of the screening device, the screening surface may be substantially parallel to the direction of the oil sands tailings fluid flow along the inlet line.
According to another aspect of the screening device, the screening surface may be open to atmosphere and may comprise an operator platform connected to the collector body enabling an operator to clean the screening surface of some of the coarse debris.
According to another aspect of the screening device, the collector body may have a bottom portion mounted on a skid such that the screening device is relocatable. The device may also comprise disconnection means for dismantling the screening device into a plurality of parts adapted for highway transport.
The present invention also provides a method for screening debris from an oil sands tailings fluid flow coming from an inlet line to pre-treat the oil sands tailings fluid flow for chemical treatment. The method comprises a step of passing the tailings fluid flow through a screen, the screen having a screening surface being configured to allow material with a predetermined size to flow through the screening surface and separate coarse debris, thereby splitting the tailings fluid flow into the coarse debris and a screened fluid flow. The method also comprises a step of collecting the screened fluid flow for further treatment.
While the invention will be described in conjunction with example embodiments, it will be understood that it is not intended to limit the scope of the invention to such embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included as defined by the present description. The objects, advantages and other features of the present invention will become more apparent upon reading of the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the screening device and the related method according to the present invention are represented in the following figures:
Figure 1 is a partially cut perspective view of a screening device according to a preferred 5 embodiment of the present invention.
Figure 2 is a schematic drawing of a screen according to a preferred embodiment of the present invention.
Figure 3 is a cross-sectional view of a pair of screening bars according to a preferred embodiment of the present invention.
Figure 4 is a perspective view of a screening device according to another preferred embodiment of the present invention.
Figure 5 is perspective view of a screening device according to another preferred embodiment of the device shown on Figure 4.
Figure 6 is a schematic cross-sectional side view of a screening device according to another preferred embodiment of the present invention.
Figure 7 is a cross-sectional side view of an inlet line according to a preferred embodiment of the present invention.
Figure 8 is a top view of a screening device according to another preferred embodiment of the present invention.
Figure 9 is a top view of the screening device shown on Figure 8 according to another preferred embodiment of the present invention.
According to another aspect of the screening device, the screening surface may be substantially parallel to the direction of the oil sands tailings fluid flow along the inlet line.
According to another aspect of the screening device, the screening surface may be open to atmosphere and may comprise an operator platform connected to the collector body enabling an operator to clean the screening surface of some of the coarse debris.
According to another aspect of the screening device, the collector body may have a bottom portion mounted on a skid such that the screening device is relocatable. The device may also comprise disconnection means for dismantling the screening device into a plurality of parts adapted for highway transport.
The present invention also provides a method for screening debris from an oil sands tailings fluid flow coming from an inlet line to pre-treat the oil sands tailings fluid flow for chemical treatment. The method comprises a step of passing the tailings fluid flow through a screen, the screen having a screening surface being configured to allow material with a predetermined size to flow through the screening surface and separate coarse debris, thereby splitting the tailings fluid flow into the coarse debris and a screened fluid flow. The method also comprises a step of collecting the screened fluid flow for further treatment.
While the invention will be described in conjunction with example embodiments, it will be understood that it is not intended to limit the scope of the invention to such embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included as defined by the present description. The objects, advantages and other features of the present invention will become more apparent upon reading of the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the screening device and the related method according to the present invention are represented in the following figures:
Figure 1 is a partially cut perspective view of a screening device according to a preferred 5 embodiment of the present invention.
Figure 2 is a schematic drawing of a screen according to a preferred embodiment of the present invention.
Figure 3 is a cross-sectional view of a pair of screening bars according to a preferred embodiment of the present invention.
Figure 4 is a perspective view of a screening device according to another preferred embodiment of the present invention.
Figure 5 is perspective view of a screening device according to another preferred embodiment of the device shown on Figure 4.
Figure 6 is a schematic cross-sectional side view of a screening device according to another preferred embodiment of the present invention.
Figure 7 is a cross-sectional side view of an inlet line according to a preferred embodiment of the present invention.
Figure 8 is a top view of a screening device according to another preferred embodiment of the present invention.
Figure 9 is a top view of the screening device shown on Figure 8 according to another preferred embodiment of the present invention.
Figure 10 is a partial schematic representation of a screening device according to another preferred embodiment of the present invention.
Figure 11 is a perspective view of a screen of the screening device shown in Figure 6.
Figure 12 is a cross-sectional view of a bottom portion of the screen shown in Figure 7.
Figure 13 is a cross-sectional view of a screening device according to another preferred embodiment of the present invention.
Figure 14 is a sectional view of the screening device shown on Figure 13.
Figure 15a is a transparent top view of a deflector spool according to another preferred embodiment of the present invention.
Figure 15b is a sectional view of the deflector spool shown on Figure 15a.
Figure 15c is a cross-sectional view of the deflector spool shown on Figure 15b.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, the same numerical references refer to similar elements. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the above-mentioned figures are preferred and given for exemplification purposes only.
Moreover, although the present invention was primarily designed for screening of an oil sands tailings fluid flow fluid, and especially for screening mature fine tailings (MFT), it may be used with other types of substance(s) and/or liquid(s), for other purposes, and in other fields, as apparent to a person skilled in the art. For this reason, expressions such as "device", "screening", "screen", "line", "pipe", "oil sands", "MFT", etc.
used herein should not be taken as to limit the scope of the present invention and includes all other kinds of items and/or applications with which the present invention could be used and may be useful.
Referring to Figure 1, the present invention provides a screening device (2) for screening debris from an oil sands tailings fluid flow. The oil sands tailings fluid flow corresponds to any tailings derived from oil sands extraction operations and may comprise mature fine tailings (MFT). MFT fluid flow that is pumped from a tailings pond by means of a dredge or barge typically includes various kinds of debris. The term "debris"
encompasses all kind of debris such as sticks, mineral lumps, solids floating around in the pond, bitumen slugs, and the like, which typically need to be screened. The oil sands tailings fluid flow is provided to the screening device through an inlet line (4) which is located above a screen (6) and distributes the tailings fluid flow on to the screen (6). The screen (6) has a screening surface which is substantially parallel to the direction of the oil sands fluid flow coming from the inlet line (4). The screen (6) separates coarse debris from the tailings fluid flow, thereby producing a screened fluid flow which flows through the screen (6) and coarse debris rejected from the screen (6). The screened, fluid flow is collected by a collector body (8) having side walls extending from the screening surface of the screen (6). The screened fluid flow contains material with a predetermined size enabling the material to flow through the screen (6) towards the collector body (8). The screened fluid flow may then be sent to downstream chemical treatments which include flocculation and dewatering treatments, such as those described in Canadian patent application Nos.
2.678.818, 2.684.232 and 2.701.317.
Referring to Figures 1 and 2, the screen comprises a plurality of screening bars (10) which are parallel to one another. They are spaced apart from each other so as to define openings (12) on either side of each supporting bar (10). The space between each screening bar is related to a maximum value of the predetermined size of the material which is allowed to pass through the screen (6). The screening bars may be spaced apart from each other with a distance ranging between about 1/2 inches and about 2.5 inches. Preferably, they may be spaced apart with a distance of about %
inches. The downstream chemical treatments determine the maximum value of the predetermined size of the material which passes through the openings (12) of the screen (6).
The maximum value preferably ranges between about 3 inches and about 4 inches. The screening bars (10) have a length ranging between about 8 feet and 12 feet and a width ranging between about 0.5in and about 1.5 inches. Preferably, the width of the top surface of the screening bars is about 3 inches. The collector body (8) is preferably a tank having a rectangular or square shape with a width of 5 feet.
The screen (6) also comprises a plurality of supporting bars (14) which are perpendicular to the screening bars (10) and connected to a bottom surface of the screening bars (10).
The screen (6) is of rectangular shape and comprises a bottom edge (16) designed to reject the separated coarse debris from the screen (6) towards a collection area. To enhance the rejection of the coarse debris, the screening surface is inclined downwardly with an angle with respect to the horizontal ranging between 25 to 45 , and preferably 30 . It allows a pushing of the coarse debris down to the bottom edge (16) of the screen (6). The screening device is thereby preferably self-cleaned from coarse debris and operates continuously.
Figure 3 offers a cross-sectional view of a pair of screening bars for illustrating a preferred technical aspect in the design of the screening bars. Each screening bar has a flow-facing surface (18), a surface opposite to the flow-facing surface (19) and side surfaces (20) extending from the flow-facing surface (18) and converging towards the opposite surface inwardly with a relieving angle ranging from about 5 to about 20 .
Preferably, the flow-facing surface (18) is a top surface and the side surfaces (20) extend downwardly and inwardly from the top surface (18). The inward tapering of the side surfaces (20) provides a corresponding opening which is outwardly tapered in the downward direction. The flow-facing surface (18) of the screening bars is therefore in direct contact with the coarse debris (21) of the incoming oil sands tailings fluid flow. The space between each flow-facing surface (18) is related to the maximum value of the predetermined size of the material (22) which is allowed to pass between the screening bars (10). The presence of the relieving angle confers to the screen a particular design which decreases the risk of plugging up the screen (6) with coarse debris (21) or accumulation of material (22). However, in case of accumulation of material and plugging of the screen, an operator can perform a cleaning easily. Indeed, the screening surface is preferably open to atmosphere which allows an operator to have a permanent view of the screen. It also enables a quick and easy access to the screening surface for performing a cleaning without requiring complex temporary dismantling of the device.
Referring to Figure 1, the inlet line of the screening device comprises a main inlet pipe (22), a box conduit (24) extending from the main inlet pipe (22) and upstream of the screen (6). An adjustable deflector plate (26) extends from the box conduit downwardly with an angle towards the screening surface to ensure a deflection of the debris towards the screen (6). The main inlet pipe (22) is closable, preferably with a knife-gate valve (28) in order to stop the oil sands tailings fluid flow from reaching the screen. This closing may be useful during cleaning operations, for example.
Figure 4 further illustrates an embodiment of the present invention wherein the screening device comprises three screening devices as described above. Indeed, the screening device may comprise a plurality of screening devices mounted adjacently and operating in parallel with respect to each other.
Referring to Figures 4, 5 and 6, the screened fluid flow collected in the collector body (8) is released from the collector body through at least one discharge outlet (30) located in a bottom portion of the collector body (8) and connected to a discharge line (32). The discharge line (32) sends the screened fluid flow to further treatments, such as flocculation and dewatering of the screened tailings. To avoid an overflowing of the collector body (8), the screened fluid flow is released from the collector body into an overflow line (34) as soon as the flow reaches at least one overflow outlet of the collector body (8). As Figure 4 illustrates, the collector body may comprise two types of overflow outlets. A first pair of overflow outlets (35) may be localised in a bottom portion of the collector body (35) and a second overflow outlet (36) may be localised in a top portion of the collector body (8) in case of an excess rise of the screened fluid flow level. The collector body may further comprise a spillbox (37) cooperating with the overflow line (34) as shown on Figure 6. When the level of the screened fluid flow increases, it may reach a top end of the spillbox (37) and flow down into the spillbox (37). The overflowing screened fluid flow is released from the spillbox through the first pair of overflow outlets (36). If the level of the overflowing screened fluid flow rises too rapidly in the spillbox because the first pair of overflow outlets (35) is not sufficient to regulate the fluid level, the second overflow outlet (36) is used to release the overflowing screened fluid flow from the spillbox (37).
As can be seen on Figures 4 and 5, in order to improve the operation of the screening device, the device also comprises an operator platform (38) which is useful to an 5 operator for monitoring the screening surface and reacting in case of plugging. The screening surface is preferably surrounded with a side enclosure (40) which extends upwardly from the collector body (8) in order to avoid tailings splashing laterally away from the screening surface which could be harmful to an operator. The screening device may be further skid-mounted (42) and semi-mobile for enabling its lifting, dragging and 10 relocation. Preferably, no single part of the screening device exceeds dimensional limitations for oversized highway transport. The screening device further comprises disconnection means for dismantling the screening device in order to be adapted for transportation.
Referring to Figure 7, the screening device comprises a removable wear plate (44) located preferably in the conduit box (24) for receiving the initial impact of the oil sands tailings fluid flow coming from the main inlet pipe (22). The flow rate of the incoming oil sands tailings fluid flow may be ranging from about 2500 USGPM to about 6000 USGPM
(from 568 m3.s 1 to about 1360 m3.s'1).
Figure 8 illustrates a screening device (103) according to another embodiment of the present invention enabling an "in-line" screening in a piping circuit. The in-line screening may be a y-joint arrangement (105) including an inlet line (107), and a lateral branch line (109). The expression "lateral" will refer to a pipe fitting which splits the oil sands tailings fluid flow into at least two directions. The branch line (109) defines an inlet opening of the inlet line (107).The branch line (109) may be a pipe acting as a collector body as mentioned above. The lateral branch line (109) forms a branching angle with respect to the inlet line (107), the branching angle being preferably about 45 degrees.
It is worth mentioning that branching off the lateral branch line (109) from the inlet line (107) can be done in various ways. As can be easily understood by a person skilled in the art, it may be done via a conventional lateral pipe fitting or simply a y-joint.
Figure 11 is a perspective view of a screen of the screening device shown in Figure 6.
Figure 12 is a cross-sectional view of a bottom portion of the screen shown in Figure 7.
Figure 13 is a cross-sectional view of a screening device according to another preferred embodiment of the present invention.
Figure 14 is a sectional view of the screening device shown on Figure 13.
Figure 15a is a transparent top view of a deflector spool according to another preferred embodiment of the present invention.
Figure 15b is a sectional view of the deflector spool shown on Figure 15a.
Figure 15c is a cross-sectional view of the deflector spool shown on Figure 15b.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, the same numerical references refer to similar elements. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the above-mentioned figures are preferred and given for exemplification purposes only.
Moreover, although the present invention was primarily designed for screening of an oil sands tailings fluid flow fluid, and especially for screening mature fine tailings (MFT), it may be used with other types of substance(s) and/or liquid(s), for other purposes, and in other fields, as apparent to a person skilled in the art. For this reason, expressions such as "device", "screening", "screen", "line", "pipe", "oil sands", "MFT", etc.
used herein should not be taken as to limit the scope of the present invention and includes all other kinds of items and/or applications with which the present invention could be used and may be useful.
Referring to Figure 1, the present invention provides a screening device (2) for screening debris from an oil sands tailings fluid flow. The oil sands tailings fluid flow corresponds to any tailings derived from oil sands extraction operations and may comprise mature fine tailings (MFT). MFT fluid flow that is pumped from a tailings pond by means of a dredge or barge typically includes various kinds of debris. The term "debris"
encompasses all kind of debris such as sticks, mineral lumps, solids floating around in the pond, bitumen slugs, and the like, which typically need to be screened. The oil sands tailings fluid flow is provided to the screening device through an inlet line (4) which is located above a screen (6) and distributes the tailings fluid flow on to the screen (6). The screen (6) has a screening surface which is substantially parallel to the direction of the oil sands fluid flow coming from the inlet line (4). The screen (6) separates coarse debris from the tailings fluid flow, thereby producing a screened fluid flow which flows through the screen (6) and coarse debris rejected from the screen (6). The screened, fluid flow is collected by a collector body (8) having side walls extending from the screening surface of the screen (6). The screened fluid flow contains material with a predetermined size enabling the material to flow through the screen (6) towards the collector body (8). The screened fluid flow may then be sent to downstream chemical treatments which include flocculation and dewatering treatments, such as those described in Canadian patent application Nos.
2.678.818, 2.684.232 and 2.701.317.
Referring to Figures 1 and 2, the screen comprises a plurality of screening bars (10) which are parallel to one another. They are spaced apart from each other so as to define openings (12) on either side of each supporting bar (10). The space between each screening bar is related to a maximum value of the predetermined size of the material which is allowed to pass through the screen (6). The screening bars may be spaced apart from each other with a distance ranging between about 1/2 inches and about 2.5 inches. Preferably, they may be spaced apart with a distance of about %
inches. The downstream chemical treatments determine the maximum value of the predetermined size of the material which passes through the openings (12) of the screen (6).
The maximum value preferably ranges between about 3 inches and about 4 inches. The screening bars (10) have a length ranging between about 8 feet and 12 feet and a width ranging between about 0.5in and about 1.5 inches. Preferably, the width of the top surface of the screening bars is about 3 inches. The collector body (8) is preferably a tank having a rectangular or square shape with a width of 5 feet.
The screen (6) also comprises a plurality of supporting bars (14) which are perpendicular to the screening bars (10) and connected to a bottom surface of the screening bars (10).
The screen (6) is of rectangular shape and comprises a bottom edge (16) designed to reject the separated coarse debris from the screen (6) towards a collection area. To enhance the rejection of the coarse debris, the screening surface is inclined downwardly with an angle with respect to the horizontal ranging between 25 to 45 , and preferably 30 . It allows a pushing of the coarse debris down to the bottom edge (16) of the screen (6). The screening device is thereby preferably self-cleaned from coarse debris and operates continuously.
Figure 3 offers a cross-sectional view of a pair of screening bars for illustrating a preferred technical aspect in the design of the screening bars. Each screening bar has a flow-facing surface (18), a surface opposite to the flow-facing surface (19) and side surfaces (20) extending from the flow-facing surface (18) and converging towards the opposite surface inwardly with a relieving angle ranging from about 5 to about 20 .
Preferably, the flow-facing surface (18) is a top surface and the side surfaces (20) extend downwardly and inwardly from the top surface (18). The inward tapering of the side surfaces (20) provides a corresponding opening which is outwardly tapered in the downward direction. The flow-facing surface (18) of the screening bars is therefore in direct contact with the coarse debris (21) of the incoming oil sands tailings fluid flow. The space between each flow-facing surface (18) is related to the maximum value of the predetermined size of the material (22) which is allowed to pass between the screening bars (10). The presence of the relieving angle confers to the screen a particular design which decreases the risk of plugging up the screen (6) with coarse debris (21) or accumulation of material (22). However, in case of accumulation of material and plugging of the screen, an operator can perform a cleaning easily. Indeed, the screening surface is preferably open to atmosphere which allows an operator to have a permanent view of the screen. It also enables a quick and easy access to the screening surface for performing a cleaning without requiring complex temporary dismantling of the device.
Referring to Figure 1, the inlet line of the screening device comprises a main inlet pipe (22), a box conduit (24) extending from the main inlet pipe (22) and upstream of the screen (6). An adjustable deflector plate (26) extends from the box conduit downwardly with an angle towards the screening surface to ensure a deflection of the debris towards the screen (6). The main inlet pipe (22) is closable, preferably with a knife-gate valve (28) in order to stop the oil sands tailings fluid flow from reaching the screen. This closing may be useful during cleaning operations, for example.
Figure 4 further illustrates an embodiment of the present invention wherein the screening device comprises three screening devices as described above. Indeed, the screening device may comprise a plurality of screening devices mounted adjacently and operating in parallel with respect to each other.
Referring to Figures 4, 5 and 6, the screened fluid flow collected in the collector body (8) is released from the collector body through at least one discharge outlet (30) located in a bottom portion of the collector body (8) and connected to a discharge line (32). The discharge line (32) sends the screened fluid flow to further treatments, such as flocculation and dewatering of the screened tailings. To avoid an overflowing of the collector body (8), the screened fluid flow is released from the collector body into an overflow line (34) as soon as the flow reaches at least one overflow outlet of the collector body (8). As Figure 4 illustrates, the collector body may comprise two types of overflow outlets. A first pair of overflow outlets (35) may be localised in a bottom portion of the collector body (35) and a second overflow outlet (36) may be localised in a top portion of the collector body (8) in case of an excess rise of the screened fluid flow level. The collector body may further comprise a spillbox (37) cooperating with the overflow line (34) as shown on Figure 6. When the level of the screened fluid flow increases, it may reach a top end of the spillbox (37) and flow down into the spillbox (37). The overflowing screened fluid flow is released from the spillbox through the first pair of overflow outlets (36). If the level of the overflowing screened fluid flow rises too rapidly in the spillbox because the first pair of overflow outlets (35) is not sufficient to regulate the fluid level, the second overflow outlet (36) is used to release the overflowing screened fluid flow from the spillbox (37).
As can be seen on Figures 4 and 5, in order to improve the operation of the screening device, the device also comprises an operator platform (38) which is useful to an 5 operator for monitoring the screening surface and reacting in case of plugging. The screening surface is preferably surrounded with a side enclosure (40) which extends upwardly from the collector body (8) in order to avoid tailings splashing laterally away from the screening surface which could be harmful to an operator. The screening device may be further skid-mounted (42) and semi-mobile for enabling its lifting, dragging and 10 relocation. Preferably, no single part of the screening device exceeds dimensional limitations for oversized highway transport. The screening device further comprises disconnection means for dismantling the screening device in order to be adapted for transportation.
Referring to Figure 7, the screening device comprises a removable wear plate (44) located preferably in the conduit box (24) for receiving the initial impact of the oil sands tailings fluid flow coming from the main inlet pipe (22). The flow rate of the incoming oil sands tailings fluid flow may be ranging from about 2500 USGPM to about 6000 USGPM
(from 568 m3.s 1 to about 1360 m3.s'1).
Figure 8 illustrates a screening device (103) according to another embodiment of the present invention enabling an "in-line" screening in a piping circuit. The in-line screening may be a y-joint arrangement (105) including an inlet line (107), and a lateral branch line (109). The expression "lateral" will refer to a pipe fitting which splits the oil sands tailings fluid flow into at least two directions. The branch line (109) defines an inlet opening of the inlet line (107).The branch line (109) may be a pipe acting as a collector body as mentioned above. The lateral branch line (109) forms a branching angle with respect to the inlet line (107), the branching angle being preferably about 45 degrees.
It is worth mentioning that branching off the lateral branch line (109) from the inlet line (107) can be done in various ways. As can be easily understood by a person skilled in the art, it may be done via a conventional lateral pipe fitting or simply a y-joint.
In this embodiment of the present invention, as illustrated on Figure 9, the oil sands tailings fluid flow is pressurized. The oil sands tailings fluid flow, preferably mature fine tailings fluid flow, is pumped from a tailings pond or holding tank into a pipeline (111). It is preferably pumped by means of a dredge in the tailings pond, more preferably at a rate of about 6000 gallons/minute. The pressurized mature fine tailings fluid flow is supplied through the pipeline (111) to a deflector spool (112) connected to the inlet line (107). The mature fine tailings fluid flow is screened from its coarse debris through the branch line (109) and is pumped with a pump for downstream chemical treatments.
In one aspect of the in-line screening device (103), two types of screens may be used.
Embodiments of the first type of screen are illustrated on Figures 10 to 12, and embodiments of the second type of screen are illustrated on Figures 13 and 14.
According to a preferred embodiment, referring to Figure 10, the screening device (103) further comprises an abutment flange (113) and a screen (115) corresponding to the first type of screen mentioned above. The abutment flange (113) is configured for abutting against a distal end (117) of the branch line (109). Flanges used for connecting onto corresponding y-fittings are well known in the art, and thus, need not to be explained in great detail herein, but it worth simply mentioning that according to a preferred embodiment, the abutment flange is preferably an ASTM 105 N class 150 blank flange, of suitable thickness, such as 1.5 inches for example. The abutment flange (113) is preferably in proportion with the y -joint arrangement (105) with which it is intended to be used. As a result, the diameter of the abutment flange (113) may vary in size depending on the inlet line (107) and corresponding branch line (109). The screen (115) comprises a least one supporting bar (119) having a distal extremity (121) extending into a screening bar (123). The screen may preferably comprise a plurality of supporting bars extending into a plurality of screening bars. The screening bars (123) and the supporting bars (119) may be preferably cylindrical. Each supporting bar (119) projects from the abutment flange (113) inwardly towards the inlet line (107) for supporting each screening bar (123) meant to be provided at a junction interface (125) between the inlet line (107) and the branch line (109). The screening bars (123) provide a screening surface being substantially parallel to a direction of mature fine tailings fluid flow along the inlet line (107). The screening surface is configured for preventing coarse debris (127) contained in the incoming oil sands fluid flow, from flowing through the screening bars (123) of the screen (115) and into the branch line (109). A screened fluid flow is thereby produced and comprises material of a predetermined size allowed to flow through the screening bars (123). The screened fluid flow is preferably pumped into the branch line (109). The screen (110) and corresponding screening surface are configured so as to be "flush"
along the inlet line (107), preferably along the junction interface (125), so as to minimize any interference with the pressurized oil sands fluid flow. The incoming oil sands fluid flow is thus split into a debris stream keeping flowing along the inlet line (107) and a screened fluid flow flowing along the branch line (109). The debris stream and the screened fluid flow preferably travel at rates of about 4000 gallons/minute and about 2000 gallons/minute, respectively. As can be easily understood by a {person skilled in the art, the screening device (103) is preferably configured so that the screening bars (123) and corresponding screening surface do not protrude into the corresponding inlet line (107) so as to not cause any disturbance within the oil sands tailings fluid flow and also, so as to avoid any clogging or plugging of the inlet line (107). However, as can be easily understood by a person skilled in the art, the screening may be performed with a plate provided with a corresponding number of suitable screening holes, each being shaped and sized for carrying out a proper screening.
According to another preferred embodiment, Figure 11 illustrates screening bars (123) which define openings (129) on either side of each bar (123). The openings (129) are shaped and sized for preventing coarse debris (127) from entering the screen (110) and flowing down the branch line (109). Preferably, the screening device (103) may comprise an odd number of screening bars (123), in which case, the screen (110) would comprise a central screening bar (123c), and a suitable number of lateral screening bars (123s), depending on the total number of screening bars (123) intended to span along the junction interface (125) and the desired screening capability, as can be easily understood by a person skilled in the art. The central screening bar (123c) may be longer than the lateral screening bars (123s). The central screening bar (123c) is supported by a pair of first and second central supporting bars (119c), and the lateral screening bars (123s) are each supported by a corresponding pair of first and second lateral supporting bars (1 19s), at least one of the central supporting bars (123c) being different in length than at least one corresponding lateral supporting bar (119s) so that a bend (131c) between the central screening bar (123c) and a corresponding central supporting bar (119c) be offset with respect to a given bend (131 s) between an adjacent lateral screening bar (123s) and a corresponding lateral supporting bar (119s). The screen (110) further comprises at least one supporting brace (133) mounted across a plurality of corresponding supporting bars (119) for providing reinforcement to said corresponding supporting bars (119). The supporting braces (133) are preferably provided at suitable locations along the supporting bars (119) for providing additional structural reinforcement and rigidity to the screen (110), and also to ensure proper positioning of the screening surface with respect to the junction interface (125).
Figure 11 and 12 illustrate the abutment flange (113) according to an embodiment of the screening device. The abutment flange may comprise a ring (135) for mounting onto the corresponding distal end (117) of the branch line (109), as is well known in the art, and according to a preferred embodiment of the present invention, where the extremities (137) of the supporting bars (119) are welded onto an inner rim (139) of the ring (135) of the abutment flange (113). Preferably also, the abutment flange (113) is provided with a suitable fastening assembly for removably fastening the abutment flange (113) onto the distal end (117) of the branch line (109). For example, the fastening assembly may comprise at least one hole (141) for receiving a corresponding fastener therethrough and into a corresponding hub (143) of the branch line (109), as is well known in the art.
Preferably also, the fastening assembly (47) comprises a plurality of holes (141) radially positioned about the abutment flange (113) in an equally spaced manner as shown on Figure 12.
According to another aspect of the in-line screening, a second type of screen (115) is provided. Referring to Figures 13 and 14, the plurality of screening bars (123) may extend over the inlet opening for preventing coarse debris flowing along the inlet line (107) from entering the branch line (109) through the inlet opening. Each screening bar (123) may be oriented substantially parallel to the direction of the oil sands tailings fluid flow along the inlet line (107). Preferably, each screening bar (123) may have a substantially rectangular section. More preferably, the screen (115) may comprise a central screening bar (123c), and a plurality of lateral screening bars (123s) being spaced apart from one another with a relieving angle with respect to the central screening bar (123c). The adjacent screening bars (123) may diverge one from another along the direction of the oil sands tailings fluid flow along the inlet line (107). Thereby, the screen has a diverging configuration which avoids pinch points along the direction of fluid flow along the inlet line and therefore reduces the risks of plugging of the screen (115). Preferably, the central screening bar (123c) may be longer than the lateral screening bars (123s).
According to another preferred embodiment, the in-line screening device (103) may further comprise a backflushing line (143) and an inspection line (145) as illustrated on Figures 8 and 9. The backflushing line (143) may be preferably branched onto the branch line (109). During possible operation downtime, a cleaning fluid, such as water, may flow through the backflushing line (143) in an opposite direction from the screened fluid flow to clean (e.g. towards the inlet line (107)) for cleaning the screen (115). The screening device (103) may further preferably comprise an inspection line (145). The inspection line (145) may be branched onto the inlet line (107) for enabling an inspection of the screen (115). An operator may thus have the possibility to detect plugging of the screen or carry out troubleshooting tasks. The inspection line (145) preferably provides an access to the screen (115).
According to another embodiment of the screening device (103), a deflector spool (112) may be used upstream to the screen (115). As shown on Figure 15, the deflector spool (112) preferably comprises a plurality of fins (147) extending along the deflector spool (112) and forming a deflecting angle with respect to the inlet line (107). The fins may deflect the coarse debris of the incoming oil sands tailings fluid flow towards the screen (115) at the intersection of the branch line (109) and into the inlet line (107).
According to another embodiment, the screening may be performed within the screening tank, the in-line screening device or a combination thereof.
The present invention also provides a method for screening debris from an oil sands tailings fluid flow coming from an inlet line to pre-treat the oil sands tailings fluid flow for chemical treatment, the screening being made according to the above-mentioned embodiments of the screening device. The method comprises the step of passing the tailings fluid flow through a screen (6, 110), the screen having a screening surface being configured to allow material with a predetermined size to flow through the screening surface and separate coarse debris, thereby splitting the tailings fluid flow into the coarse debris and a screened fluid flow as better shown on Figure 1 and 6. The method further comprises a step of collecting the screened fluid flow in a collector body (8, 109) for 5 further chemical treatment. As previously mentioned, the oil sands tailings fluid flow may be a mature fine tailings fluid flow.
The method may further comprise a step of providing the oil sands tailings fluid flow in a direction substantially parallel to the screening surface along the inlet line. The direction of the incoming fluid flow has a considerable impact on the efficiency of the screening.
10 The method may also comprise a step of deflecting the oil sands tailings fluid flow coming from the inlet line towards the screen. This deflecting may be performed by the adjustable deflector plate (26) in case of screening with the screening tank as illustrated on Figures 1 to 7. The deflecting may further be performed by the deflector spool (112) in case of the in-line screening as illustrated on Figures 8 to 15. According to another 15 preferred embodiment, the method may comprise a step of rejecting the coarse debris from a bottom edge of the screen towards a collection area. Even if the screen used in the present method is a self-cleaning screen, a plugging with coarse debris may occur.
That is the reason why the method may also comprise a step of closing the inlet line during cleaning operations of the screen.
According to another aspect of the method, a step of discharging the screen fluid flow from a bottom portion of the collector body into a discharge line may be performed. A
further step of releasing the screen fluid flow from a top portion of the collector body into an overflow line may also be performed. The steps of the method may be repeated for a plurality of screens adjacent to each other and operating in parallel.
The description and drawings of the screening device and method are intended to help the understanding of the invention rather than to limit its scope. It will be apparent to one skilled in the art that various modifications may be made to the invention without departing from what has actually been invented.
In one aspect of the in-line screening device (103), two types of screens may be used.
Embodiments of the first type of screen are illustrated on Figures 10 to 12, and embodiments of the second type of screen are illustrated on Figures 13 and 14.
According to a preferred embodiment, referring to Figure 10, the screening device (103) further comprises an abutment flange (113) and a screen (115) corresponding to the first type of screen mentioned above. The abutment flange (113) is configured for abutting against a distal end (117) of the branch line (109). Flanges used for connecting onto corresponding y-fittings are well known in the art, and thus, need not to be explained in great detail herein, but it worth simply mentioning that according to a preferred embodiment, the abutment flange is preferably an ASTM 105 N class 150 blank flange, of suitable thickness, such as 1.5 inches for example. The abutment flange (113) is preferably in proportion with the y -joint arrangement (105) with which it is intended to be used. As a result, the diameter of the abutment flange (113) may vary in size depending on the inlet line (107) and corresponding branch line (109). The screen (115) comprises a least one supporting bar (119) having a distal extremity (121) extending into a screening bar (123). The screen may preferably comprise a plurality of supporting bars extending into a plurality of screening bars. The screening bars (123) and the supporting bars (119) may be preferably cylindrical. Each supporting bar (119) projects from the abutment flange (113) inwardly towards the inlet line (107) for supporting each screening bar (123) meant to be provided at a junction interface (125) between the inlet line (107) and the branch line (109). The screening bars (123) provide a screening surface being substantially parallel to a direction of mature fine tailings fluid flow along the inlet line (107). The screening surface is configured for preventing coarse debris (127) contained in the incoming oil sands fluid flow, from flowing through the screening bars (123) of the screen (115) and into the branch line (109). A screened fluid flow is thereby produced and comprises material of a predetermined size allowed to flow through the screening bars (123). The screened fluid flow is preferably pumped into the branch line (109). The screen (110) and corresponding screening surface are configured so as to be "flush"
along the inlet line (107), preferably along the junction interface (125), so as to minimize any interference with the pressurized oil sands fluid flow. The incoming oil sands fluid flow is thus split into a debris stream keeping flowing along the inlet line (107) and a screened fluid flow flowing along the branch line (109). The debris stream and the screened fluid flow preferably travel at rates of about 4000 gallons/minute and about 2000 gallons/minute, respectively. As can be easily understood by a {person skilled in the art, the screening device (103) is preferably configured so that the screening bars (123) and corresponding screening surface do not protrude into the corresponding inlet line (107) so as to not cause any disturbance within the oil sands tailings fluid flow and also, so as to avoid any clogging or plugging of the inlet line (107). However, as can be easily understood by a person skilled in the art, the screening may be performed with a plate provided with a corresponding number of suitable screening holes, each being shaped and sized for carrying out a proper screening.
According to another preferred embodiment, Figure 11 illustrates screening bars (123) which define openings (129) on either side of each bar (123). The openings (129) are shaped and sized for preventing coarse debris (127) from entering the screen (110) and flowing down the branch line (109). Preferably, the screening device (103) may comprise an odd number of screening bars (123), in which case, the screen (110) would comprise a central screening bar (123c), and a suitable number of lateral screening bars (123s), depending on the total number of screening bars (123) intended to span along the junction interface (125) and the desired screening capability, as can be easily understood by a person skilled in the art. The central screening bar (123c) may be longer than the lateral screening bars (123s). The central screening bar (123c) is supported by a pair of first and second central supporting bars (119c), and the lateral screening bars (123s) are each supported by a corresponding pair of first and second lateral supporting bars (1 19s), at least one of the central supporting bars (123c) being different in length than at least one corresponding lateral supporting bar (119s) so that a bend (131c) between the central screening bar (123c) and a corresponding central supporting bar (119c) be offset with respect to a given bend (131 s) between an adjacent lateral screening bar (123s) and a corresponding lateral supporting bar (119s). The screen (110) further comprises at least one supporting brace (133) mounted across a plurality of corresponding supporting bars (119) for providing reinforcement to said corresponding supporting bars (119). The supporting braces (133) are preferably provided at suitable locations along the supporting bars (119) for providing additional structural reinforcement and rigidity to the screen (110), and also to ensure proper positioning of the screening surface with respect to the junction interface (125).
Figure 11 and 12 illustrate the abutment flange (113) according to an embodiment of the screening device. The abutment flange may comprise a ring (135) for mounting onto the corresponding distal end (117) of the branch line (109), as is well known in the art, and according to a preferred embodiment of the present invention, where the extremities (137) of the supporting bars (119) are welded onto an inner rim (139) of the ring (135) of the abutment flange (113). Preferably also, the abutment flange (113) is provided with a suitable fastening assembly for removably fastening the abutment flange (113) onto the distal end (117) of the branch line (109). For example, the fastening assembly may comprise at least one hole (141) for receiving a corresponding fastener therethrough and into a corresponding hub (143) of the branch line (109), as is well known in the art.
Preferably also, the fastening assembly (47) comprises a plurality of holes (141) radially positioned about the abutment flange (113) in an equally spaced manner as shown on Figure 12.
According to another aspect of the in-line screening, a second type of screen (115) is provided. Referring to Figures 13 and 14, the plurality of screening bars (123) may extend over the inlet opening for preventing coarse debris flowing along the inlet line (107) from entering the branch line (109) through the inlet opening. Each screening bar (123) may be oriented substantially parallel to the direction of the oil sands tailings fluid flow along the inlet line (107). Preferably, each screening bar (123) may have a substantially rectangular section. More preferably, the screen (115) may comprise a central screening bar (123c), and a plurality of lateral screening bars (123s) being spaced apart from one another with a relieving angle with respect to the central screening bar (123c). The adjacent screening bars (123) may diverge one from another along the direction of the oil sands tailings fluid flow along the inlet line (107). Thereby, the screen has a diverging configuration which avoids pinch points along the direction of fluid flow along the inlet line and therefore reduces the risks of plugging of the screen (115). Preferably, the central screening bar (123c) may be longer than the lateral screening bars (123s).
According to another preferred embodiment, the in-line screening device (103) may further comprise a backflushing line (143) and an inspection line (145) as illustrated on Figures 8 and 9. The backflushing line (143) may be preferably branched onto the branch line (109). During possible operation downtime, a cleaning fluid, such as water, may flow through the backflushing line (143) in an opposite direction from the screened fluid flow to clean (e.g. towards the inlet line (107)) for cleaning the screen (115). The screening device (103) may further preferably comprise an inspection line (145). The inspection line (145) may be branched onto the inlet line (107) for enabling an inspection of the screen (115). An operator may thus have the possibility to detect plugging of the screen or carry out troubleshooting tasks. The inspection line (145) preferably provides an access to the screen (115).
According to another embodiment of the screening device (103), a deflector spool (112) may be used upstream to the screen (115). As shown on Figure 15, the deflector spool (112) preferably comprises a plurality of fins (147) extending along the deflector spool (112) and forming a deflecting angle with respect to the inlet line (107). The fins may deflect the coarse debris of the incoming oil sands tailings fluid flow towards the screen (115) at the intersection of the branch line (109) and into the inlet line (107).
According to another embodiment, the screening may be performed within the screening tank, the in-line screening device or a combination thereof.
The present invention also provides a method for screening debris from an oil sands tailings fluid flow coming from an inlet line to pre-treat the oil sands tailings fluid flow for chemical treatment, the screening being made according to the above-mentioned embodiments of the screening device. The method comprises the step of passing the tailings fluid flow through a screen (6, 110), the screen having a screening surface being configured to allow material with a predetermined size to flow through the screening surface and separate coarse debris, thereby splitting the tailings fluid flow into the coarse debris and a screened fluid flow as better shown on Figure 1 and 6. The method further comprises a step of collecting the screened fluid flow in a collector body (8, 109) for 5 further chemical treatment. As previously mentioned, the oil sands tailings fluid flow may be a mature fine tailings fluid flow.
The method may further comprise a step of providing the oil sands tailings fluid flow in a direction substantially parallel to the screening surface along the inlet line. The direction of the incoming fluid flow has a considerable impact on the efficiency of the screening.
10 The method may also comprise a step of deflecting the oil sands tailings fluid flow coming from the inlet line towards the screen. This deflecting may be performed by the adjustable deflector plate (26) in case of screening with the screening tank as illustrated on Figures 1 to 7. The deflecting may further be performed by the deflector spool (112) in case of the in-line screening as illustrated on Figures 8 to 15. According to another 15 preferred embodiment, the method may comprise a step of rejecting the coarse debris from a bottom edge of the screen towards a collection area. Even if the screen used in the present method is a self-cleaning screen, a plugging with coarse debris may occur.
That is the reason why the method may also comprise a step of closing the inlet line during cleaning operations of the screen.
According to another aspect of the method, a step of discharging the screen fluid flow from a bottom portion of the collector body into a discharge line may be performed. A
further step of releasing the screen fluid flow from a top portion of the collector body into an overflow line may also be performed. The steps of the method may be repeated for a plurality of screens adjacent to each other and operating in parallel.
The description and drawings of the screening device and method are intended to help the understanding of the invention rather than to limit its scope. It will be apparent to one skilled in the art that various modifications may be made to the invention without departing from what has actually been invented.
Claims (77)
1- A screening device for screening debris from an oil sands tailings fluid flow coming from an inlet line to pre-treat the oil sands tailings fluid flow for chemical treatment, the screening device comprising :
a screen having a screening surface being configured to allow material with a predetermined size to flow through the screening surface and separate coarse debris, thereby splitting the tailings fluid flow into coarse debris and a screened fluid flow; and a collector body having side walls extending from the screening surface and configured to receive the screened fluid flow for the chemical treatment.
a screen having a screening surface being configured to allow material with a predetermined size to flow through the screening surface and separate coarse debris, thereby splitting the tailings fluid flow into coarse debris and a screened fluid flow; and a collector body having side walls extending from the screening surface and configured to receive the screened fluid flow for the chemical treatment.
2- The screening device according to claim 1, wherein the oil sands tailings are mature fine tailings.
3- The screening device according to claim 1 or 2, wherein the screen comprises a plurality of screening bars, the screening bars being spaced apart from each other so as to define openings on either side of each bar, the openings being sized and shaped for only allowing the material of the predetermined size to flow through the screen towards the collector body.
4- The screening device according to claim 3, wherein the screening bars are substantially parallel to one another.
5- The screening device according to claim 4, wherein the screening bars have a flow-facing surface and side surfaces, the side surfaces extending from the flow-facing surface inwardly with a relieving angle with respect to the flow-facing surface.
6- The screening device according to claim 5, wherein the flow-facing surface is top surface facing upward and the side surfaces extend downwardly from the top surface.
7- The screening device according to claim 5 or 6, wherein the relieving angle ranges between about 5° and about 20 °.
8- The screening device according to claim 7, wherein the relieving angle is about 8°
9- The screening device according to any one of claims 3 to 8, wherein the screen comprises a plurality of supporting bars, the supporting bars being perpendicular to the screening bars and connected to a bottom surface of the screening bars.
10-The screening device according to any one of claims 3 to 9, wherein the screening bars have a length ranging between about 8 feet and 12 feet.
11-The screening device according to any one of claims 3 to 10, wherein the screening bars have a width ranging between about 1/2 inches and about 2 inches.
12- The screening device according to claim 10, wherein the width of each of the screening bars is about 3/4 inches.
13-The screening device according to any one of claims 3 to 12, wherein the screening bars are spaced apart from each other with a distance ranging between about 1/2 inches and about 2.5 inches.
14- The screening device according to claim 13, wherein the supporting bars are spaced apart from each other with a distance of about 18 inches.
15-The screening device according to any one of claims 1 to 14, wherein the screening surface is of rectangular shape.
16-The screening device according to any one of claims 1 to 15, wherein the predetermined size of the material flowing through the screening surface has a maximum value enabling a downstream flocculation and dewatering treatment of the oil sands tailings.
17- The screening device according to any one of claims 1 to 16, wherein the predetermined size of the material flowing through the screening surface has a maximum value ranging between about 1/4 inches and about 6 inches.
18- The screening device according to any one of claims 1 to 17, wherein the screening surface is substantially parallel to the direction of the oil sands tailings fluid flow along the inlet line.
19- The screening device according to any one of claims 1 to 18, wherein the screening surface is inclined downwardly with an angle with respect to the horizontal and sufficient to allow pushing of the coarse debris down the screen and their rejection over a bottom edge of the screen.
20- The screening device according to claim 19, wherein the screen has a bottom edge arranged to allow the coarse debris to be rejected.
21- The screening device according to claim 20, wherein the screening surface is inclined downwardly with an angle ranging between about 25° and about 45°.
22-The screening device according to claim 21, wherein the screening surface is inclined downwardly with an angle of about 30°.
23- The screening device according to any one of claims 1 to 22, wherein the screening surface is open to atmosphere.
24- The screening device according to claim 23, comprising an operator platform connected to the collector body enabling an operator to clean the screening surface of some of the coarse debris.
25- The screening device according to any one of claims 1 to 24, further comprising a side enclosure extending upwardly from the collector body around the screening surface for avoiding tailings splashing laterally away from the screening surface.
26- The screening device according to any one of claims 1 to 25, further comprising a collection area collecting the coarse debris flow pushed down the screening surface in the direction of the inlet line.
27- The screening device according to any one of claims 1 to 26, wherein the inlet line comprises a removable wear plate receiving an initial impact of the oil sands tailings fluid flow.
28- The screening device according to any one of claims 1 to 27, wherein the inlet line further comprises a closable main inlet pipe distributing the oil sands tailings fluid flow into a box conduit located upstream of the screen and setting the direction of the oil sands tailings fluid flow before contacting the screening surface.
29- The screening device according to claim 28, wherein the closable main inlet pipe comprises a knife-gate valve for closing the main inlet pipe and stopping the oil sands fluid flow in case of screen plugging.
30- The screening device according to claim 28 or 29, wherein the removable wear plate is located inside the box conduit.
31-The screening device according to any one of claims 28 to 30, further comprising an adjustable deflector plate extending from the box conduit downwardly with an angle towards the screening surface to ensure a deflection of the debris towards the screen.
32-The screening device according to any one of claims 1 to 31, wherein the collector body has a bottom portion and wherein the screening device comprises a discharge line connected to a discharge outlet of the bottom portion of the collector body and releasing the screened fluid flow out of the collector body through the outlet for the chemical treatment.
33- The screening device according to any one of claims 1 to 32, wherein the collector body has a top portion and wherein the screening device comprises an overflow line connected to an overflow outlet of the top portion of the collector body and collecting the screened fluid flow overflowing the collector body through the overflow outlet.
34- The screening device according to claim 33, wherein the collector body comprises a spillbox collecting the overflowing screened fluid flow, the overflowing screened fluid flow being released from the spillbox through the overflow outlet into the overflow line.
35- The screening device according to any one of claims 1 to 34, wherein the collector body has a bottom portion mounted on a skid such that the screening device is relocatable.
36- The screening device according to any one of claims 1 to 35, further comprising disconnection means for dismantling the screening device into a plurality of parts adapted for highway transport.
37- The screening device according to any one of claims 1 to 36, wherein the collector body is a tank.
38-The screening device according to any one of claims 1 to 37, wherein the oil sands tailings fluid flow coming from a inlet line has a flow rate ranging between about 568 M3. s-1 and about 1360 m3.s-1.
39-The screening device according to any one of claims 1 to 38, wherein the screening device is a first screening device and the device also comprises a second screening device mounted adjacently and operating in parallel with the first screening device.
40-The screening device according to claim 3, wherein the collector body comprises a branch line branched onto the inlet line, forming an inlet opening therebetween, for enabling in-line screening, the branch line forming a branching angle with respect to the inlet line.
41-The screening device according to claim 40, wherein the branching angle is about 45 degrees.
42- The screening device according to claims 40 or 41, wherein the branch line is a pipe.
43- The screening device according to any one of claims 40 to 42, wherein the branch line has a distal end comprising an abutment flange.
44- The screening device according to claim 43, wherein the abutment flange comprises a ring.
45- The screening device according to claim 43 or 44, wherein the abutment flange is provided with a fastening assembly for removably fastening the abutment flange onto the distal end of the branch line.
46-The screening device according to claim 45, where the fastening assembly comprises at least one hole for receiving a corresponding fastener therethrough and into a corresponding hub of the branch line.
47-The screening device according to claim 45 or 46, wherein the fastening assembly comprises a plurality of holes radially positioned about the abutment flange in an equally spaced manner.
48- The screening device according to any one of claims 43 to 47, wherein the screen comprises a plurality of supporting bars, each supporting bar projecting from the abutment flange inwardly towards the inlet opening and along the branch line, each supporting bar being operatively connected to a corresponding screening bar of the screen for supporting said corresponding screening bar, each screening bar being oriented along the inlet line.
49-The screening device according to claim 48, wherein each supporting bar is operatively connected to each corresponding screening bar by a bend.
50-The screening device according to claim 48 or 49, wherein each screening bar and each supporting bar are cylindrical.
51-The screening device according to any one of claims 48 to 50, wherein each screening bar is positioned at an angle of about 45 degrees with respect to the corresponding supporting bar.
52-The screening device according to any one of claims 48 to 51, wherein the screen comprises screening bars of different length.
53-The screening device according to any one of claims 48 to 52, wherein the screen comprises supporting bars of different length.
54- The screening device according to any one of claims 48 to 53, wherein the screen comprises a central screening bar, and a plurality of lateral screening bars, the central screening bar being longer than the lateral screening bars.
55- The screening device according to any one of claims 48 to 54, wherein the spacing between the screening bars of the screen is variable.
56- The screening device according to any one of claims 48 to 55, wherein the screen comprises at least one supporting brace mounted across a plurality of corresponding supporting bars for providing reinforcement to said corresponding supporting bars.
57- The screening device according to any one of claims 48 to 56, wherein extremities of supporting bars are welded onto an inner rim of the ring of the abutment flange.
58- The screening device according to any one of claims 40 to 47, wherein the plurality of screening bars extends over the inlet opening, each screening bar being oriented substantially parallel to the direction of the oil sands tailings fluid flow along the inlet line, for preventing coarse debris flowing along the inlet line from entering the branch line through the inlet opening.
59- The screening device according to claim 58, wherein each screening bar has a substantially rectangular section.
60- The screening device according to claim 58 or 59, wherein the screen comprises a central screening bar, and a plurality of lateral screening bars being spaced apart from one another with a relieving angle with respect to the central screening bar, such that adjacent screening bars diverge one from another along the direction of the oil sands tailings fluid flow along the inlet line.
61- The screening device according to claim 60, wherein the central screening bar is longer than the lateral screening bars.
62- The screening device according to any one of claims 40 to 61, further comprising a pump for pumping the oil sands tailings fluid flow through the screen into the branch line.
63- The screening device according to any one of claims 40 to 62, further comprising a backflushing line branched onto the branch line, the backflushing line enabling a backflushing fluid to flow through the screen from the branch line towards the inlet line to clean the screen.
64-The screening device according to any one of claims 40 to 63, further comprising an inspection line branched onto the inlet line, the inspection line enabling an inspection of the screen, plugging detection, and providing access to the screen for maintenance purposes.
65- The screening device according to any one of claims 40 to 64, further comprising a deflector spool branched upstream to the inlet line.
66- The screening device according to claim 65, wherein the deflector spool comprises a plurality of fins defining a deflecting angle with respect to the inlet line for deflecting the coarse debris towards the screen.
67- A method for screening debris from an oil sands tailings fluid flow coming from an inlet line to pre-treat the oil sands tailings fluid flow for chemical treatment, the method comprising the steps of:
a) passing the tailings fluid flow through a screen, the screen having a screening surface being configured to allow material with a predetermined size to flow through the screening surface and separate coarse debris, thereby splitting the tailings fluid flow into the coarse debris and a screened fluid flow; and b) collecting the screened fluid flow in a collector body for further treatment.
a) passing the tailings fluid flow through a screen, the screen having a screening surface being configured to allow material with a predetermined size to flow through the screening surface and separate coarse debris, thereby splitting the tailings fluid flow into the coarse debris and a screened fluid flow; and b) collecting the screened fluid flow in a collector body for further treatment.
68-The method according to claim 67, wherein the oil sands tailings are mature fine tailings.
69-The method according to claim 67 or 68, further comprising a step of providing the oil sands tailings fluid flow in a direction substantially parallel to the screening surface along the inlet line.
70-The method according to any one of claim 67 to 69, further comprising a step of deflecting the oil sands tailings fluid flow coming from the inlet line towards the screen.
71- The method according to any one of claims 67 to 70, further comprising a step of rejecting the coarse debris from a bottom edge of the screen towards a collection area.
72- The method according to any one of claims 67 to 71, further comprising a step of discharging the screen fluid flow from a bottom portion of the collector body into a discharge line.
73-The method according to any one of claims 67 to 72, further comprising a step of releasing the screen fluid flow from a top portion of the collector body into an overflow line.
74- The method according to any one of claims 67 to 73, further comprising a step of closing the inlet line during cleaning operations of the screen.
75- The method according to any one of claims 67 to 74, further comprising a step of relocating the screen with transportation means.
76- The method according to any one of claims 67 to 75, wherein the screen is a first screen and the method comprises passing the oil sands tailings fluid flow through a second screen adjacent to the first screen and operating in parallel.
77- A method for screening debris from an oil sands tailings fluid flow coming from an inlet line to pre-treat the oil sands tailings fluid flow for chemical treatment, the method comprising the steps of:
a) providing a screening device as claimed in any one of claims 1 to 66;
b) passing the tailings fluid flow through said screening device; and c) collecting the screened fluid flow with said collector body for the chemical treatment.
a) providing a screening device as claimed in any one of claims 1 to 66;
b) passing the tailings fluid flow through said screening device; and c) collecting the screened fluid flow with said collector body for the chemical treatment.
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2733873 CA2733873A1 (en) | 2011-03-14 | 2011-03-14 | Device and method for screening pre-treatment of oil sands tailings |
| PCT/CA2012/050149 WO2012122646A1 (en) | 2011-03-14 | 2012-03-13 | Pre-treatment of fine tailings by coarse debris removal |
| CA2772053A CA2772053C (en) | 2011-03-14 | 2012-03-13 | Pre-treatment of fine tailings by coarse debris removal |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2733873 CA2733873A1 (en) | 2011-03-14 | 2011-03-14 | Device and method for screening pre-treatment of oil sands tailings |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2733873A1 true CA2733873A1 (en) | 2012-09-14 |
Family
ID=46827130
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2733873 Abandoned CA2733873A1 (en) | 2011-03-14 | 2011-03-14 | Device and method for screening pre-treatment of oil sands tailings |
| CA2772053A Active CA2772053C (en) | 2011-03-14 | 2012-03-13 | Pre-treatment of fine tailings by coarse debris removal |
Family Applications After (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2772053A Active CA2772053C (en) | 2011-03-14 | 2012-03-13 | Pre-treatment of fine tailings by coarse debris removal |
Country Status (2)
| Country | Link |
|---|---|
| CA (2) | CA2733873A1 (en) |
| WO (1) | WO2012122646A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111790587A (en) * | 2020-08-04 | 2020-10-20 | 中铁九局集团工程检测试验有限公司 | Needle-shaped broken pebble screening device and method |
Families Citing this family (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9005434B2 (en) | 2011-10-27 | 2015-04-14 | Cedar Creek Filters, Lllp | Water filter |
| CA2892983C (en) * | 2013-01-18 | 2017-09-19 | Basf Se | Treatment of fine tailings |
| US20160030864A1 (en) * | 2013-03-12 | 2016-02-04 | Robert A. Anderson | Suspended solids filter system |
| CN110216057A (en) * | 2019-05-20 | 2019-09-10 | 中国神华能源股份有限公司 | Sand sieving machine |
| CN110394292B (en) * | 2019-08-02 | 2021-07-23 | 南京江宁区上峰国银标准件厂 | Energy-saving environment-friendly intelligent mechanical equipment for urban construction |
| CN112452698A (en) * | 2020-11-02 | 2021-03-09 | 安徽泰恩康制药有限公司 | Drying and screening equipment for processing Chinese patent medicine pills |
| CN116571438B (en) * | 2023-05-25 | 2023-12-12 | 江苏金红新材料股份有限公司 | Sorter and separation method for separating garnet and titanium ore mixture |
| CN117101852B (en) * | 2023-10-23 | 2023-12-26 | 内蒙古中和实业有限公司 | Sophora alopecuroide seed flotation device and application method thereof |
| CN117798062A (en) * | 2024-03-01 | 2024-04-02 | 凯美塑化科技(烟台)有限公司 | Masterbatch granule screening plant |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US8147682B2 (en) * | 2006-10-31 | 2012-04-03 | Syncrude Canada Ltd. | Bitumen and thermal recovery from oil sand tailings |
| CA2653058A1 (en) * | 2009-02-16 | 2010-08-16 | Jan Kruyer | Dewatering oil sand fine tailings using revolving oleophilic apertured wall |
| CA2705055C (en) * | 2010-05-20 | 2015-11-03 | Suncor Energy Inc. | Method and device for in-line injection of flocculent agent into a fluid flow of mature fine tailings |
-
2011
- 2011-03-14 CA CA 2733873 patent/CA2733873A1/en not_active Abandoned
-
2012
- 2012-03-13 WO PCT/CA2012/050149 patent/WO2012122646A1/en active Application Filing
- 2012-03-13 CA CA2772053A patent/CA2772053C/en active Active
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111790587A (en) * | 2020-08-04 | 2020-10-20 | 中铁九局集团工程检测试验有限公司 | Needle-shaped broken pebble screening device and method |
| CN111790587B (en) * | 2020-08-04 | 2022-06-03 | 中铁九局集团工程检测试验有限公司 | Needle-shaped broken pebble screening device and method |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2012122646A1 (en) | 2012-09-20 |
| CA2772053C (en) | 2015-12-29 |
| CA2772053A1 (en) | 2012-09-14 |
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