This application claims priority to Great Britain Patent Application No. 1902635.0 filed Feb. 27, 2019, and Great Britain Patent Application No. 1902726.7 filed Feb. 28, 2019 and Great Britain Patent Application No. 1914520.0 filed Oct. 8, 2019. The contents of each of these applications are hereby incorporated herein by reference for all purposes.
In mining operations there is a need to store tailings, products resulting from the ore extraction process. Typically these are retained in tailings pits or tailings lagoons behind a tailings dam. Typically the tailings dam can begin as a low level dam and be built up to a greater height periodically as mining progresses to accommodate tailings as these are produced. Solid tailings are often used as part of the dam structure.
Over the last 50 years, over 1800 people have been killed as a result of tailings dam “ruptures” in different places around the world, the last two events having been in Minas Gerais Brazil.
All these tailings dam “ruptures” were the direct result of hydraulic pressure being exerted on the manmade dam which more often than not is built out of local waste mineral materials that are compacted to form the dam at the lower part of the dam/valley.
More often than not, it is the fluidisation of the slurry behind the dam that results in the full hydraulic pressure to the depth of the tailings slurry acting on the dam especially in flat face rather than curved face dams.
Some of the “ruptures” are caused by flood rain taking the water level in the dam to above the design limit but the mine operators have not developed adequate mechanisms of removing excess rain water from the lower part of the dam. This excess of rain water that sits against the inner edge of the dam again has the effect of fluidising the settled tailings slurry and also fluidising the compacted dam itself.
Many tailings dam designs (except dams constructed from concrete) often have horizontal water drain pipes built into the bottom of the dam walls which whilst initial filling of the tailings dam with tailings these pipes are kept closed, but as the tailings slurry increases in height in the dam, these pipes are used to vent water that has seeped to the bottom of the tailings dam wall to the downstream side of the dam. This removal of water assists in ensuring the slurry behind the dam for up to 100 meters upstream of the dam dries out and does not become fluidised.
The most frequent problem is that these water drainage pipes at the bottom of the dam wall that vent water from the upstream side of the dam to the other side of the dam downstream become blocked or fractured and no longer are able to take the water away. This happens especially when the dam is not maintained or when production has stopped for one reason or another at the metal mine that produces the by-product tailings. It can also be a problem that the sheer quantity of rain ends up raising the water level in the dam and it overspills and fluidises the toe of the dam.
The end result of blocked dam water drainage pipes is fluidisation of the settled slurry behind the dam and even the fluidisation of the dam itself of which either or both can easily result in the rupture of the dam and catastrophic dam failure.
The present application relates to a mechanism and process that will mitigate against fluidisation of tailings material close to the dam wall on tailings pits that have been inactive for a period of time or that are active but are considered at risk of “Rupture”.
The issues with tailings pits that are considered at risk of “Rupture” is that the risk of them being inherently unsafe, nobody wants to venture out onto the dam or into the tailings lagoon and even if they did, they are uncertain how to remove water and or de-fluidise the tailings especially towards the centre of the dam.
The present invention relates to a method of dewatering a tailings lagoon retained by a dam comprising: excavating an excavation hole in the tailings lagoon; allowing water from surrounding tailings to enter the excavation hole; and pumping water in the excavation hole out of the excavation hole and discharging beyond a toe of the dam. Thus the tailings surrounding the excavation holes are dewatered and the possibility of hydrostatic pressure acting on the dam is reduced.
In an embodiment a pontoon floats in water in the excavation hole and supports equipment used for the step of pumping water.
In an embodiment before excavating the excavation hole, excavating a channel in the tailings lagoon from a shore of the tailings lagoon to a location at which the excavation hole is to be excavated and floating the pontoon from the shore to the excavation hole along the channel. This is a safe way to get the equipment necessary for excavating the excavation hole and for providing water to the pontoon down the excavated channel for density control of the slurry generated from the tailings being excavated for the area near the dam.
In an embodiment excavating involves breaking down solid (i.e settled) tailings in the tailings lagoon into a slurry using water and removing the slurry using a slurry pump mounted on the pontoon. In an embodiment the excavating involves breaking down solid tailings in the tailings lagoon into a slurry using water and removing the slurry using at least two submersible slurry pumps (or at least one submersible slurry pump and at least one water pump (submersible, horizontal or other type)) mounted on the pontoon. This way of excavating is efficient and avoids needing to dig out tailings, which can be more dangerous and time consuming, particularly if the water content of the tailings is high.
In an embodiment during the excavating the water for breaking down the solid tailings is supplied by the pontoon preferably from a shore supply or from excess surface water on the tailings dam. This speeds up breaking down of tailings and therefore excavation.
In an embodiment the water supplied by the pontoon is at least partly water extracted from the channel, which may be supplied from a shore supply or that the channel has collected from surface water, on the pontoon and/or excavation hole by the pontoon.
In an embodiment during the excavating water is provided to the pontoon from a shore of the tailings lagoon. This speeds up excavation if water content in the tailings at the site of excavation is low.
In an embodiment water is supplied to the channel and/or excavation hole during excavation from beyond the tailings lagoon. This speeds up excavation if water content in the tailings at the site of excavation is low.
In an embodiment the amount of water contained in the slurry is controlled to be a certain minimum amount. This ensures that any pipes through which the slurry is transported from the pontoon to a discharge location can be prevented from being blocked with slurry which has too low a water content.
In an embodiment the pontoon is controlled remotely from a shore of the tailings lagoon and can be run unmanned for significant periods. This enhances safety.
In an embodiment dewatering is localised to tailings adjacent the dam. This is efficient as it is the tailings closest to the dam wall which must be prevented from fluidizing. If the tailings closest to the dam wall have low water content, the presence of such tailings helps hold back tailings further up the lagoon away from the dam with a higher water content.
In an embodiment the present invention provides a method comprising excavating a channel in a tailings lagoon from a shore of the tailings lagoon and floating a pontoon in water in the channel from the shore along the channel, wherein excavating involves breaking down solid tailings in the tailings lagoon into a slurry using water and removing the slurry using a slurry pump mounted on the pontoon. This method allows solidified tailings from a tailings lagoon to be broken down into a slurry for easy transport of the broken down tailings. The tailings may then be moved to a different position and/or reprocessed to extract certain materials contained in the tailings which were not previously removed. For example, new techniques may allow greater extraction of a material such as a precious metal contained in the tailings than was possible when the tailings was originally produced. Alternatively, new techniques or changes in the value of materials may mean that the tailings may be reprocessed to remove materials not previously removed from the tailings.
All of the techniques described herein relating to excavating the channel in a dewatering method apply equally to the above described method of excavating a channel.
The present invention will be described by way of example only with reference to the following drawings in which:
Below is a description of an embodiment to make dams which retain a tailings lagoon at “risk” more inherently safe by ensuring the tailings behind the dam, say 25 or more meters down and up to the surface and up to 100 meters from the dam wall is not subjected to high water content and thus the material in the dam above this level will not become fluidised and as such will stop exerting hydraulic force on the dam wall and will actually assist the dam wall hold back tailings material higher up the tailings lagoon. By de-fluidising the tailings from the surface to 25 or more meters down and from the dam to 100 or more meters upstream of the dam, it will also ensure that the dam itself does not become fluidised. The figures 25 m down and up to the surface and up to 100 m from the dam wall are examples and the method can be used to de-water a to a shallower level or to a deeper level and closer or further from the dam wall.
If dewatering to a greater depth using a submersible pump, a pressure compensator reservoir may need to be fitted to the pump motor housing.
To carry out this dewatering operation, two submersible slurry pump pontoons can be used with one submersible slurry pump and one water submersible pump on each pontoon. These modular section quick build pontoons can be constructed on the edge of the lagoon 100 meters upstream of the dam, one on a first (e.g the left hand looking towards the dam from below the dam wall) side of the lagoon and one on the other (e.g. right hand) side of the lagoon. These pontoons would make a channel filled with water through the tailings for themselves to float along by pumping water jetting and pumping slurry towards the upper end of the lagoon (e.g. 750 meters up the lagoon) such that the pontoons end up on either side of the centre line of the dam (e.g. 75 meters either side) and a distance (e.g. 100 meters) from the dam.
These pontoons would be operational 95% or more of the time from the shore and would be controlled from a shore based control cabin linked to the pontoons with e.g. cables or wirelessly, for example by radio signals or industrial WiFi, thus minimising the risk of operators being out in the tailings lagoon when there is a risk of dam rupture.
Each pontoon having used it's submersible slurry pump with a water submersible or other type of water pump and density control system to ensure the concentration of solids did not go above a predetermined level (say above 40% by volume) would be used to create in their location an excavated pool (for example 30 to 50 meters in diameter) that was tapered as it went down (e.g. to a depth of up 25 meters, or if needed 50 meters with a pressure compensating reservoir fitted to the submersible pump.
This excavation hole (perhaps conical in shape) would naturally find water draining into it from the tailings. The water would convert the settled tailings from anything between 70% solids to 40% solids into slurry. The slurry can then be pumped out and up the lagoon using the submersible slurry pump. If there was not enough water available, which might happen if the creation of the conical hole was done in the dry season, water would be supplied additionally down the channel the pontoon has created from the shore.
Once the excavation of the two excavation holes has been completed, then the pontoon and submersible pumps would be used to pump water that flowed into the excavation holes along a pipe to the downstream side of the dam. This can be achieved with flexible pipes that are led over the top of the dam. If this process is kept running 24 hours per day then dewatering of the dam in the most critical areas would be very much improved especially if the water drain pipes from the bottom of the dam were blocked.
Also when there is rain water coming down the lagoon towards the dam it would naturally migrate to the two excavation holes via the channels excavated from the shore such that it could be pumped away by the submersible pumps. This process is designed to keep the water table in the tailings lagoon near the dam wall between 10 and 20 or more meters below where it would naturally be and thus prevent fluidisation of tailings material along the dam wall and near the centre of the dam which is its weakest point and also assist in preventing the fluidisation of the dam itself as occurred at Bento Rodrigues/Samarco.
Exactly the same techniques can be used for the purpose of reprocessing or repositioning solid (i.e. settled) tailings. That is the excavation techniques described can be used to break down solid (i.e. settled) tailings in a tailings lagoon into a slurry and remove the slurry using a slurry pump mounted on the pontoon. That slurry may then be reprocessed or repositioned. This technique can be used whilst carving a channel in a tailings lagoon or at any desired location within the tailings lagoon where an excavation hole is excavated.
The process and apparatus will now be described with reference to the figures.
The pontoon 10 comprises at least one float 20. In the example of
A submersible slurry pump 50, such as that available from Goodwin, is installed onto the framework 40. In an embodiment a submersible pump 60 is installed onto the framework 40. The submersible pump 60 may be a slurry pump or a water pump mounted in some manner to the pontoon 10. In an embodiment the two pumps 50,60 are attached at opposite ends of the pontoon 10. The submersible pumps 50,60 can be raised and lowered from the framework 40, so that the distance of extraction by the pumps 50,60 from the pontoon 10 can be varied. In another embodiment the submersible pumps 50 and or 60 are mounted in fixed position relative to the deck of the pontoon 10 and so are fixed in the horizontal position.
In the method, a trench 110 is dug into the tailings 80 of the lagoon from the shore 70. The trench may, for example, measure 15 m long (10-20 m long), 12 m wide (5-18 m wide) and 3.5 m deep (1.5 to 5 m deep) (
The pontoon 10 is connected to the shore so that electricity, control signals and/or water can be provided to the pontoon 10, depending upon its needs. For example the pontoon 10 may have its own generator installed, or may rely on power being provided from the shore. Water can be provided to the pontoon 10 by providing water from the shore 70 into the trench 110 (and into the channel 128 and/or excavation hole 150 described below) which then flows to the pontoon 10. A pump (e.g. pump 60) of the pontoon 10 then collects water from under the pontoon 10 for use by the pontoon 10. The flow of water may be controlled dependent upon the density of tailings in the water being consumed by the pontoon 10.
As illustrated in
The submersible slurry pump 50 may also have its own source of water, and it expels water 89 to help breakdown tailings 80 at the location at which it is extracting slurry. For this purpose a pipe 91 provides water to the submersible slurry pump 50 and a separate pipe 120 removes the slurry, for disposal elsewhere. Material breakdown and pumping is thereby accelerated by the submersible slurry pump. A jetting ring can be fitted to the slurry pump to jet the water against the solid tailings and thereby accelerate breakdown. Jetting can also be achieved from a plurality, e.g four (one or more) jets, for example mounted on each corner of the pontoon 10. These jets have a dual purpose _Hydro propulsion, and preferably directional control, for the pontoon 10 and jetting of solid tailings 80 in the lagoon.
The water pump 60 on the pontoon 10 and the piping and measuring and control system on the pontoon 10 is used for controlling the density of the slurry being pumped out by the slurry pump 50 (for example via a density control circuit). For example the amount of water in jet 89 and/or jet 85 is controlled. The tailings in the lagoon may have a water content of between 20% and 70%. If you try to pump slurries with water contents below 40% by volume there is a high chance of the slurry pipe blocking. So control is applied to provide water at a rate which ensures the slurry being pumped has a water content above, for example 30% or 35%, preferably above 40%. The provision of water to the pontoon 10 (for example along the channel 128 or through pipes from the shore), is controlled so that the appropriate water content in the excavated slurry is present. In an embodiment there may be one or more additional optional booster pumps 250 (see
In the case that the lagoon has a layer of water on top of the tailings 80, it may not be necessary to excavate a trench 110 and channel 128 as described above with reference to
Once the pontoons are in position in the lagoon, for example 100 m from the dam wall 5 (e.g 200-20 m from the dam wall, preferably 150-50 m from the dam wall) and, in the case to two pontoons 10 being used, each 75 m from the lagoon centreline (e.g. 20-100 m from the centreline), the pontoons 10 stop excavating the channel 128. Thus the excavation holes are positioned in the tailings lagoon such that dewatering is localised to tailings adjacent the dam wall 5. The pontoons 10 then start to excavate holes 150 in the tailings 80 (
The depth of the excavation hole 150 is desirably greater than the depth of the channel 128 leading to it. In an embodiment the diameter of the excavation hole 150 is greater than the width of the channel 128 leading to it.
Once the excavation holes 150 are dug in the tailings 80 and the slurry pumping stops, water from the surrounding tailings 80 will drain into the excavation holes 150 (illustrated as 160 in
The slurry that will be discharged due to the creation of the channels 128 and/or dewatering holes 150 upstream of the dam wall 5 may optionally be captured in geotextile cloth bags to reduce turbidity (cloudiness) of any effluent water discharged downstream of the dam 5 whilst capturing the tailings to prevent further environmental contamination moving the tailings from their present location.
The dewatering holes 150 created to reduce the hydraulic pressure of the dam wall 5, once created, may optionally have installed a high volume submersible pump capable of handling dirty water, typically they would be similar to those found at the entrances to underground mines that prevent underground mines flooding during rainy seasons or flash rainfall, being able to cope with high volumes of dirty water (typically from 0% up to 15% solids) on an ad hoc basis to further reduce the possibility of any standing water anywhere on the tailings pit.
Although the invention is described using two pontoons 10, any number of pontoons 10 can be used. For example, only one pontoon 10 may be used, or three or more may be used, depending on the desired speed and extent of dewatering and the size of the lagoon.
Number | Date | Country | Kind |
---|---|---|---|
1902635.0 | Feb 2019 | GB | national |
1902726.7 | Feb 2019 | GB | national |
1914520.0 | Oct 2019 | GB | national |