Patent Application
20090133987
1. Field of the Invention
This invention relates generally to mining and more particularly to processing a sized ore feed.
2. Description of Related Art
Surface mining operations are generally employed to excavate an ore deposit that is found near the surface. Such ore deposits are usually covered by an overburden of rock, soil, and/or plant matter, which may be removed prior to commencing mining operations. The remaining ore deposit may then be excavated and transported to a plant for processing to remove commercially useful products. For example, the ore deposit may comprise an oil sand deposit from which hydrocarbon products may be extracted.
In the example of an oil sand ore deposit, such as the Northern Alberta Tar Sands, the ore deposit comprises about 70 to about 90 percent by weight of mineral solids including sand and clay, about 1 to about 10 percent by weight of water, and a bitumen or oil film. The bitumen may be present in amounts ranging from a trace amount up to as much as 20 percent by weight. Consequently, since oil sand ore deposits comprises a relatively small percentage by weight of bitumen, it is generally more efficient and cost effective to at least partially separate the bitumen from the ore as soon as possible after excavation, since significant energy costs are incurred in transporting the ore over long distances.
In commonly owned Canadian Patent Application No. 2,567,644, a process line for mining an oil sands ore body is disclosed. The process line includes an excavator for mining oil sands ore, a comminutor for receiving mined ore from the excavator and comminuting the mined ore to conveyable size and transferring the comminuted ore to a mobile conveyor for transporting the comminuted ore. The comminutor supplies conveyable ore to the mobile conveyor, and the mobile conveyor is periodically moved in an arc about a discharge end to locate another portion of the ore body within operational reach of the mobile conveyor until substantially all of the ore body within operational reach of the conveyor has been mined. In one disclosed embodiment the ore is transported to a mobile slurry facility located proximate a mine face of an oil sand deposit. Operation of the disclosed process line requires that the overburden be removed, either prior to commencing excavation or as the conveyor advances in the operational arc. Following mining of the ore deposit, the slurry facility may be relocated to a subsequent mine face for excavation of a subsequent portion of the ore body. Accordingly, the disclosed process line facilitates successively mining generally circular sectors of the ore deposit.
One embodiment provides a method for processing a sized ore feed excavated from an ore deposit. The method involves disposing a processing apparatus in a processing apparatus position relative to the ore deposit, and disposing a first mobile conveyor to receive a sized ore feed at a receiving location located along a length of the first mobile conveyor. The first mobile conveyor is operable to convey the sized ore from the receiving location to a discharge end of the first mobile conveyor. The method also involves disposing a second mobile conveyor to receive the sized ore from the discharge end of the first mobile conveyor at a transfer location along a length of the second mobile conveyor and to convey the sized ore from the transfer location to the processing apparatus. The first and second mobile conveyors are oriented at an operational angle between a length of the first mobile conveyor and a length of the second mobile conveyor. The method further involves moving at least one of the first and second mobile conveyors to vary at least one of the operational angle and the transfer location to permit successive portions of the ore deposit within operational reach of the receiving location to be received for conveying along the first and second mobile conveyors to the processing apparatus while the processing apparatus is located in the processing apparatus position.
The ore deposit may include at least one portion within operational reach of the receiving location that is not to be excavated and moving at least one of the first and second mobile conveyors may involve varying at least one of the operational angle and the transfer location to move the receiving location around the at least one portion that is not to be excavated.
Receiving the sized ore feed at the receiving location may involve receiving the sized ore feed proximate at least one of a plurality of receiving locations along the length of the first mobile conveyor.
Receiving the sized ore feed at the at least one of the plurality of receiving locations may involve receiving the sized ore feed at a hopper mounted for movement on a track extending along at least a portion of the length of the first mobile conveyor.
Receiving the sized ore feed may involve receiving ore from an excavator and comminuting the ore to produce the sized ore feed.
Receiving the ore from the excavator may involve receiving the ore in a load carrying container and transporting the ore to a comminutor for comminuting the ore.
Disposing the processing apparatus may involve disposing the processing apparatus at an angle to a mine face of the ore deposit to provide clearance between the second mobile conveyor and the processing apparatus when moving the second mobile conveyor.
In a first operational stage disposing the first mobile conveyor may involve disposing the first mobile conveyor to position the receiving location of the first mobile conveyor at a distal mine face location with respect to the processing apparatus position, disposing the second mobile conveyor may involve causing the second mobile conveyor to be disposed to discharge the sized ore into a feeder of the processing apparatus, and moving at least one of the first and second mobile conveyors may involve causing the second mobile conveyor to successively move toward the mine face about the feeder while causing the first mobile conveyor to progressively advance into the ore deposit while excavating a first portion of the ore deposit within operational reach of the receiving location.
Disposing the second mobile conveyor to receive the sized ore from the discharge end of the first mobile conveyor may involve disposing the second mobile conveyor to receive the sized ore at a transfer location proximate an end of the second mobile conveyor that may be distally located with respect to the discharge end of the second mobile conveyor.
In a second operational stage disposing the second mobile conveyor may involve causing the second mobile conveyor to be disposed generally parallel to the mine face, and moving the at least one of the first and second mobile conveyors may involve causing the first mobile conveyor to be laterally translated while successively moving the transfer location along the second mobile conveyor toward the feeder of the processing apparatus while maintaining the operational angle substantially constant to permit excavation of a second portion of the ore deposit within operational reach of the receiving location.
Maintaining the operational angle substantially constant may involve maintaining an operational angle of about 90 degrees.
In a third operational stage disposing the second mobile conveyor may involve causing the second mobile conveyor to be moved to position the transfer location on an opposite side of the feeder of the processing apparatus, and moving the at least one of the first and second mobile conveyors may involve moving the first mobile conveyor to place the discharge end of the first mobile conveyor at the transfer location, and causing the first mobile conveyor to be laterally translated while successively moving the transfer location along the second mobile conveyor away from the feeder of the processing apparatus while maintaining the operational angle substantially constant to permit excavation of a third portion of the ore deposit within operational reach of the receiving location.
In a fourth operational stage moving the at least one of the first and second mobile conveyors may involve causing the first and second mobile conveyors to be disposed at an operational angle of about 180 degrees such that the first and second mobile conveyors may be generally in-line with each other to permit excavation of distally located portions of the ore deposit within operational reach of the receiving location.
Moving at least one of the first and second mobile conveyors may involve moving both the first mobile conveyor and the second mobile conveyor while varying the operational angle to permit excavation along a generally linear mine face portion of the ore deposit.
The processing apparatus position may be a first processing apparatus position and the method may further involve, on completion of excavation of the successive portions of the ore deposit within operational reach of the receiving location, relocating the processing apparatus to a second processing apparatus position to permit excavation of further portions of the ore deposit while the processing apparatus may be located in the second processing apparatus position.
In accordance with another aspect of the invention there is provided a process line apparatus for processing a sized ore feed excavated from an ore deposit. The apparatus includes a processing apparatus disposed in a processing apparatus position relative to the ore deposit, and a first mobile conveyor disposed to receive a sized ore feed at a receiving location located along a length of the first mobile conveyor. The first mobile conveyor is operable to convey the sized ore from the receiving location to a discharge end of the first mobile conveyor. The apparatus also includes a second mobile conveyor disposed to receive the sized ore from the discharge end of the first mobile conveyor at a transfer location along a length of the second mobile conveyor and to convey the sized ore from the transfer location to the processing apparatus. The first and second mobile conveyors are oriented at an operational angle between a length of the first mobile conveyor and a length of the second mobile conveyor. The apparatus also includes provisions for moving at least one of the first and second mobile conveyors to vary at least one of the operational angle and the transfer location to permit successive portions of the ore deposit within operational reach of the receiving location to be to be excavated and received for conveying along the first and second mobile conveyors to the processing apparatus while the processing apparatus is located in the processing apparatus position.
The ore deposit may include at least one portion within operational reach of the receiving location that is not to be excavated and the provisions for moving at least one of the first and second mobile conveyors may include provisions for varying at least one of the operational angle and the transfer location to move the receiving location around the at least one portion that is not to be excavated.
The receiving location may include at least one of a plurality of receiving locations along the length of the first mobile conveyor.
The first mobile conveyor may be operably configured to receive the sized ore feed at a hopper mounted for movement on a track extending along at least a portion of the length of the first mobile conveyor.
The apparatus may include an excavator for excavating ore from the ore deposit, and a comminutor for receiving the excavated ore from the excavator and comminuting the ore to produce the sized ore feed.
The apparatus may include a load carrying container for transporting the ore between the excavator and the comminutor.
The processing apparatus may be disposed at an angle to a mine face of the ore deposit to provide clearance between the second mobile conveyor and the processing apparatus when moving the second mobile conveyor.
The first mobile conveyor and the second mobile conveyor each may include a plurality of conveyor sections, each conveyor section including provisions for moving the conveyor section, and alignment provisions for aligning the plurality of conveyor sections.
The provisions for moving at least one of the first and second mobile conveyors may include provisions for moving both the first mobile conveyor and the second mobile conveyor while varying the operational angle to permit excavation along a generally linear mine face portion of the ore deposit.
Another embodiment provides a process line apparatus for processing a sized ore feed excavated from an ore deposit. The apparatus includes a processing apparatus disposed in a processing apparatus position relative to the ore deposit, and a first mobile conveyor disposed to receive a sized ore feed at a receiving location located along a length of the first mobile conveyor, the first mobile conveyor being operable to convey the sized ore from the receiving location to a discharge end of the first mobile conveyor. The apparatus also includes a second mobile conveyor disposed to receive the sized ore from the discharge end of the first mobile conveyor at a transfer location along a length of the second mobile conveyor and to convey the sized ore from the transfer location to the processing apparatus. The first and second mobile conveyors are oriented at an operational angle between a length of the first mobile conveyor and a length of the second mobile conveyor, and the first mobile conveyor and the second mobile conveyor are operably configured to move to vary at least one of the operational angle and the transfer location to permit successive portions of the ore deposit within operational reach of the receiving location to be excavated and received for conveying along the first and second mobile conveyors to the processing apparatus while the processing apparatus is located in the processing apparatus position.
The ore deposit may include at least one portion within operational reach of the receiving location that is not to be excavated and the first and second mobile conveyors may be operably configured to vary at least one of the operational angle and the transfer location to move the receiving location around the at least one portion that is not to be excavated.
The receiving location may include at least one of a plurality of receiving locations along the length of the first mobile conveyor.
The first mobile conveyor may be operably configured to receive the sized ore feed at a hopper mounted for movement on a track extending along at least a portion of the length of the first mobile conveyor.
The apparatus may include an excavator for excavating ore from the ore deposit, and a comminutor for receiving the excavated ore from the excavator and comminuting the ore to produce the sized ore feed.
The apparatus may include a load carrying container for transporting the ore between the excavator and the comminutor.
Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
In drawings which illustrate embodiments of the invention,
Referring to
The apparatus 102 also includes a first mobile conveyor 104 disposed to receive a sized ore feed at a receiving location 106 located along a length of the first mobile conveyor. The first mobile conveyor 104 is operable to convey the sized ore from the receiving location 106 to a discharge end 108 of the first mobile conveyor.
The apparatus 102 further includes a second mobile conveyor 110 disposed to receive the sized ore from the discharge end 108 of the first mobile conveyor 104 at a transfer location 112 along a length of the second mobile conveyor. The second mobile conveyor 110 conveys the sized ore from the transfer location 112 to the processing apparatus 116.
The first and second mobile conveyors 104 and 110 are oriented at an operational angle γ between the length of the first mobile conveyor and the length of the second mobile conveyor. The first mobile conveyor 104 and the second mobile conveyor 108 are also operably configured to move to vary the operational angle γ and/or the transfer location 112 to permit successive portions of the ore deposit within operational reach of the receiving location to be to be excavated and received for conveying along the first and second mobile conveyors to the processing apparatus 116.
In the embodiment shown in
In the embodiment shown, the apparatus 102 also includes an excavator 124 for excavating the ore from the mine face 120, and a comminutor 126 for producing the sized ore feed. The comminutor 126 generally crushes larger chunks of the excavated ore to produce an ore feed having a maximum portion size that is conveyable by the first and second mobile conveyors 104 and 110.
In one embodiment the ore deposit 100 comprises a bituminous ore, having a substantial portion of mineral solids such as sand and clay, water, and a bitumen and/or oil film. Bituminous ore may comprise up to about 20 percent bitumen by weight, and processing the ore involves separating the bitumen from the sand, clay, water, and other trace constituents. Processing of bituminous ore may involve a plurality of processing steps such as producing a bitumen ore slurry. In other embodiments the ore deposit 100 may comprise other minerals and/or constituents that are to be extracted from ore excavated during in an open pit or strip mining operation, for example. Alternatively, the process line apparatus 102 may be used to remove an overburden layer overlying an ore deposit.
Referring to
Referring to
Each conveyor section 202-208 includes at least one support 212 having crawler tracks 214 for moving the conveyor section. In this embodiment dual tracks 214 are provided facilitating movement of the conveyor sections in both transverse and longitudinal directions. The dual tracks 114 have the advantage of providing additional stability when it is desired to move the mobile conveyor 200 in the longitudinal direction.
In general the supports 212 and/or crawler tracks 214 may be independently height adjustable to accommodate changes in terrain height between conveyor sections 202-208. In the embodiment shown each conveyor section 202-208 includes an alignment gauge 216 for producing an alignment signal representing a misalignment condition between adjacent conveyor sections. The alignment gauge 216 produces signals representing lateral and/or height misalignment conditions between adjacent conveyor sections. The alignment gauge 216 may include a string pot (otherwise known as a cable extension transducer), for example.
The mobile conveyor 200 also includes a hopper 218, which may act as the receiving location 106, for example. The hopper 218 may be mounted for movement along a track (not shown) extending at least partway along the length of the mobile conveyor 200, to permit the receiving location 106 to be successively disposed at different locations along the mobile conveyor as required. Alternatively the conveyor 200 may be configured to provide a plurality of spaced apart locations at which the hopper may be located. In other embodiments, an additional hopper (not shown) may be included to permit sized ore to be simultaneously receiving at more than one receiving location.
In this embodiment the discharge conveyor section 208 includes an upwardly inclined conveyor portion 220 that acts as the discharge end 108. The discharge conveyor section 208 also includes an alignment sensor 222 that produces a signal for monitoring a location of the discharge end 108 with respect to a receiving location (such as a hopper 224 located on another conveyor section 168). The alignment sensor 222 produces a feedback signal for controlling the movement of the crawler tracks 214 on the discharge conveyor section 208 by monitoring the relative location of the discharge end 108 with respect to the hopper 224. The alignment sensor 222 may be an optical sensor, for example.
Generally, the mobile conveyor 200 also includes a controller (not shown) for activating the crawler tracks 214 in response to the alignment signals produced by the alignment gauges 216 and the feedback signal produced by the alignment sensor 222. In operation, the controller produces control signals for driving the crawler tracks 214 and the supports 212 to maintain the conveyor sections 202-208 in a generally straight line condition with the discharge end 108 aligned over the hopper 224. The mobile conveyor 200 may be moved about the discharge end 108 by moving the first conveyor section 202, thereby causing the conveyor sections 204, 206, and 208 to subsequently move to maintain the conveyor 200 in a straight line. Should the conveyor be required to move over uneven terrain, the controller may also produce height adjustment signals in response to the alignment signals produced by the alignment gauges 216 to cause the supports 212 to be adjusted to maintain the conveyor sections 202-208 in a generally level condition. The mobile conveyor 200 may also be laterally translated and/or longitudinally repositioned by causing each of the conveyor sections 202-208 to be moved substantially in the same direction and by the same amount.
By using conveyor sections 202-208 as modular units, the first and second mobile conveyors 104 and 110 may be easily assembled as required for excavating a particular ore deposit 100 and by adding one or more conveyor sections, may be extended to provide a greater operational reach, if required.
Suitable mobile and/or portable conveyor sections are manufactured by FLSmidth RAHCO Inc. of Spokane, Wash., USA and FAM of Magdeburg, Germany.
Referring to
In operation, hot water is generally introduced at the inlet chute 254 and at the roller screen 260. The hot water reduces ore buildup in the inlet chute 254 and the roller screen 260. In some embodiments further additives and/or cold water may be added as required. The combination of ore, water, and other additives produces a slurry which is accumulated in the slurry box 256. The slurry box 256 may be dimensioned such that, for an average ore feed rate through the inlet chute 254, the slurry retention time in the slurry box is approximately one minute. The slurry box 256 also includes an outlet 266 in communication with a hydro-transport pump 268. The hydro-transport pump 268 is in communication with a hydro-transport pipeline 270, and pumps bitumen slurry from the slurry box 256 through the hydro-transport pipeline to a plant (not shown) for further processing of the bitumen slurry.
In the embodiment shown, the slurry apparatus 253 also includes crawler tracks 272 on the slurry box 256, and crawler tracks 252 on the transfer conveyor 250 for relocating the slurry apparatus to subsequent processing apparatus positions 154, 158, 162, 166, and 170 shown in
A suitable mobile slurry apparatus is disclosed in commonly owned Canadian Patent Application No. 2,610,169 entitled “Method and Apparatus for Creating a Slurry.”
In other embodiments, where the ore comprises minerals other than bitumen, the processing apparatus 116 may include various other processing stages, which may or may not produce a slurry of the sized ore.
The excavator 124 and comminutor 126 are shown in side view in
The comminutor 126 includes a set of comminuting rollers 306 for comminuting or crushing the excavated ore to produce a sized ore feed that is suitable for conveying by the first and second mobile conveyors 104 and 110. In one embodiment the comminuting rollers 306 are sized and spaced to produce a sized ore feed having no chunks having a diameter of greater than about 350 mm. The comminutor 126 also includes an apron feeder 308 for conveying the excavated ore from the hopper 128 to the comminuting rollers 306. The comminutor 126 also includes a discharge conveyor 309, having a receiving end 310 and a discharge end 316. The sized ore feed is received from the comminuting rollers 306 at the receiving end 310, and is conveyed to the discharge end 316 where the sized ore is transferred to the receiving location 106 of the first mobile conveyor 104.
In general the comminutor 126 includes controls and sensors (not shown) for controlling the passage of ore from the apron feeder 308, through the comminuting rollers 306, and to the discharge conveyor 309. For example, various controls may be employed to slow down or speed up the apron feeder 308 and the discharge conveyor 309 to produce a generally even rate of sized ore feed to the first mobile conveyor 104. Sensors may also be employed to detect the occurrence of metal and/or large chunks, and to slow or halt the ore feed through the apparatus to appropriately deal with these occurrences. The comminutor 126 may also include a screen (not shown) ahead of the comminuting rollers 306 to reject oversize chunks of ore.
In an alternative embodiment, load carrying containers such as haul trucks (not shown) may be employed during at least some of the excavation operation. The load carrying container receives ore from the excavator 124 and transports the ore to the comminutor 126, thereby extending the operational reach of the excavator. However in general, it is desirable to limit the use of haul trucks by generally maintaining the excavator 124 and comminutor 126 within operational reach of each other to reduce overall excavation cost.
As described above in connection with
Referring to
The second mobile conveyor 110 is positioned such that the discharge end 114 is over the hopper 118 of the processing apparatus 116, and the second mobile conveyor is oriented at an angle β to the longitudinal axis 352 of the processing apparatus, as shown at 356. In general the angle β is selected to provide operating clearance between the second mobile conveyor 104 and the processing apparatus 116 during mining operations. In one embodiment the angle β is about 108°.
The first mobile conveyor 104 is positioned such that the discharge end 108 is proximate the transfer location 112, and the first mobile conveyor is oriented at an operational angle γ between the length of the first mobile conveyor 104 and the length of the second mobile conveyor 110, as shown at 358 in
The comminutor 126 is located such that the discharge end 316 of the discharge conveyor 309 is proximate the receiving location 106 of the first mobile conveyor 104. The orientation of the second mobile conveyor 110 (i.e., the angle β) and the operational angle γ between the first and second mobile conveyors are selected to permit the excavator 124 to excavate the ore deposit 100 at a distal mine face portion 360.
In general, the bitumen containing ore deposit is covered by an overburden layer of sand, rock, and vegetation, which has little or no bitumen content. The overburden layer is typically removed in advance to prevent conveying ore to the processing apparatus 116 that does not carry any economic value. The overburden may be removed in its entirety prior to commencing excavation, or may be removed in sections ahead of the conveyor being advanced to permit excavation of the corresponding ore deposit section.
Referring to
In the embodiment shown in
Advantageously, by operating first and second mobile conveyors 104 and 110 at a varying operational angle γ, a generally linear portion of the mine face such as the mine face 380 may be excavated along a boundary such as the boundary 152 shown in
In other embodiments more than one spaced apart receiving locations (not shown) along the first mobile conveyor 104 may be simultaneously employed to further increase the excavation rate and the sized ore feed rate, if required.
Referring to
Referring to
The first mobile conveyor 104 may need to be moved to permit the rotation of the second mobile conveyor, whereafter the first mobile conveyor is then moved to place the discharge end 108 at the transfer location 112, which is initially located proximate the discharge end 108. Alternatively, if permitted by the terrain, the second mobile conveyor may be moved away from the processing apparatus 116 for rotating, thereby permitting excavation to continue using the first mobile conveyor 104. In this case the discharge end 108 of the first mobile conveyor 104 is located to discharge sized ore directly into the hopper 118 of the processing apparatus 116. When the second mobile conveyor 110 has been reconfigured, it may be moved back into operation as shown in
Referring to
Referring to
Advantageously, excavation of the first, second, and third portions 378, 392, and 410 as described above results in an extensive section of the ore deposit 100 being excavated while the processing apparatus 116 remains located in the first processing apparatus position. By moving both the first and second mobile conveyors 104 and 110, the process line 102 facilitates excavation of linear walls along the mine face and/or excavation of substantially rectangular sections of ore.
In one embodiment the first mobile conveyor may be about 240 meters in length and the second mobile conveyor may be about 200 meters in length, which facilitates excavation of a section having a mine face of about 710 meters wide and extending about 270 meters into the mine face (i.e., in a direction away from the processing apparatus position).
Referring to
Referring back to
Referring back to
During these movements of the first and second mobile conveyors 104 and 110, receiving of the sized ore may be temporarily suspended until the respective conveyors are repositioned. At this time the excavator 124 and comminutor 126 may be moved into position for continuing excavation along a mine face 446 of the portion 440. Operations then generally continue as described above and excavation continues along the generally linear mine face 446 and a further portion 448 is excavated while leaving the portion 440 un-excavated.
Advantageously, using first and second mobile conveyors 104 and 110 configurable at the varying angle γ facilitates mining around the portion 140. Prior art process lines would require the portion 440 to be excavated and removed to permit the conveyor to pass in its operational arc. Furthermore, by permitting the portion 440 to remain unexcavated, it is not necessary to remove the overburden above the portion 440. Removal of overburden represents an un-recoverable cost in excavating an ore deposit since the overburden has little or no economic value. Furthermore removing the need to process low grade ore advantageously increases the proportion of bitumen containing ore in the total volume of ore that is excavated, thereby improving operational efficiency.
While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2,526,336 | Nov 2005 | CA | national |
This application is a continuation-in-part of U.S. patent application Ser. No. 11/938,189 entitled “METHOD AND APPARATUS FOR CREATING A SLURRY” filed on Nov. 9, 2007. This application hereby incorporates by reference U.S. patent application Ser. No. 11/558,303 entitled “METHOD AND APPARATUS FOR CREATING A SLURRY” filed on Nov. 9, 2006 and Canadian Patent Application No. 2,526,336 filed on Nov. 9, 2005 in their entireties.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11938189 | Nov 2007 | US |
| Child | 12242642 | US |
