Note: Descriptions are shown in the official language in which they were submitted.
CA 02915349 2015-12-15
ROTARY BREAKING FOR CREATING AN OIL SAND SLURRY
FIELD OF THE INVENTION
This invention relates to ore processing. In particular, this invention
relates
to a method and apparatus for creating a slurry from oil sand ore.
BACKGROUND OF THE INVENTION
Oil sand ore, also referred to as tar sand ore, is found in certain
geographical locations. For example, the Northern Alberta Oil Sands are
considered to be one of the world's largest remaining oil reserves. The oil
sands
are typically composed of about 70 to about 90 percent by weight mineral
solids,
including sand and clay, about 1 to about 10 percent by weight water, and
bitumen, that comprises from trace amounts up to as much as 21 percent by
weight. Typically ores containing a lower percentage by weight of bitumen
contain a higher percentage by weight of fine mineral solids ("fines") such as
clay
and silt.
Oil sand ore is abrasive as the bitumen is locked onto mineral grains. In
order to commercially mine oil sand ore, large volumes of ore must be rapidly
processed with the addition of process fluid to extract the bitumen from the
mineral material. The resulting slurry of mined oil sand ore and process fluid
is
highly abrasive. The commercial viability of an ore body is dependent in part
upon the volume of oil sand ore that may be processed over a period of time.
In
particular, processing frozen ore is extremely difficult due to its resistance
to
comminution.
Unlike conventional oil deposits, the bitumen is extremely viscous and
difficult to separate from the water and mineral mixture in which it is found.
Initially, the oil sand is excavated from its location and passed through a
crusher
or comminutor to comminute the chunks of ore into smaller pieces. The
comminuted ore is then typically combined with process fluid to aid in
liberating
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the oil. Process fluid may be water, or a combination of water and one or more
process aids. The combined oil sand and process fluid is typically referred to
as a
"slurry". Other agents, such as additional process aids or flotation aids may
be
added to the slurry. Process fluid is commonly heated to assist in breaking
down
mined oil sand ore and release entrapped bitumen.
The slurry is then passed through a "conditioning" phase in which the
slurry is allowed to mix and dwell for a period to create froth in the
mixture. The
term "conditioning" generally refers to a process whereby sufficient energy
has
been expended such that the bitumen has left the mineral component to form an
entity capable of recovery. The extent of conditioning is influenced by the
characteristics imparted to the slurry during its preparation. Such
characteristics
include the lump size, slurry density, amount of mechanical energy imparted to
the slurry, amount of thermal energy imparted to the slurry, aeration of the
slurry
and the addition of chemicals (if any). Once the slurry has been conditioned,
it is
typically passed through a series of separators for removing the bitumen froth
from the slurry.
An apparatus for preparing an oil sand slurry, known to those skilled in the
art as a rotary breaker, is described in Canadian Patent 2,235,938 (the '938
patent). The objective of a rotary breaker is to comminute sized oil sand ore,
produce an oil sand slurry, and selectively filter out rocks and other hard
material,
likely not containing bitumen. The described rotary breaker generally
comprises a
rotatable perforated tube, having a feed end and a discharge end. Mined ore
and
process fluid, such as hot process water, are injected into the rotary breaker
at
the feed end. Rotation of the tube causes the ore slurry to be lifted and
tumbled,
comminuting the ore lumps. The water and ore lumps of a predetermined size
pass through the perforations of the rotatable tube, while the oversized lumps
traverse through the vessel, towards the discharge end. Any oversize ore lumps
reaching the discharge end are ejected out of the vessel. Ejected oil sand ore
may preferably be returned to the feed end for re-processing while ejected
rock
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and clay material may be discarded. The ore that has passed through the
perforations is collected beneath the rotatable tube for hydro-transport.
The operation of a rotary breaker such as that described in the '938 patent
may be improved to allow for higher feed rates of oil sand ore to be
processed.
Since large volumes of mineral solids must be processed to extract the
bitumen,
increasing the feed rate may improve the economics of the process. This may
allow for the processing of oil sand with a wider range of bitumen
concentrations
economically. Ideally a rotary breaker will reduce all of the infeed mined oil
sand
ore to granular material for passage through the perforations of the rotatable
vessel.
It has become known that rotary breakers used to prepare an oil sand
slurry are prone to backflow, wherein the mined ore deposited in the rotary
breaker accumulates at the feed end of the breaker, and discharges back out of
the feed end of the breaker, instead of either being broken down to pass
through
the perforations or being ejected out the discharge end. Backflow in rotary
breakers typically occurs when mined oil sand ore infeed rates are increased,
depending upon the condition and composition of the mined oil sand ore.
An additional problem faced by rotary breakers used to prepare an oil
sand slurry is occlusion of the perforations by previously deposited oil sand,
blocking newly deposited oil sand from passing through the perforations.
Occlusion of the perforations leads to reduced throughput of slurry, increased
ejection of material and increases the likelihood that oil sand will backflow
out of
the feed end of the rotary breaker.
A further problem faced by rotary breakers used to prepare an oil sand
slurry, is sufficiently wetting the infeed oil sand ore when infeed rates are
increased.
Accordingly there is a need for improving the efficiency of a rotary breaker
used to prepare an oil sand slurry. There is a need for a rotary breaker and
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method of operating a rotary breaker that allow for higher oil sand
throughput.
There is a need for a rotary breaker and method of operating a rotary breaker
that reduce the likelihood that oil sand backflows out of the rotary breaker.
BRIEF DESCRIPTION OF THE DRAWINGS
In drawings, which illustrate by way of example only, embodiments of the
invention,
Figure 1 is an isometric view of a rotatable breaker tube.
Figure 2 is a schematic view of an interior surface of an embodiment of a
rotatable breaker tube.
Figures 3a to 3d are cutaway views of alternative embodiments of
perforations in the rotatable breaker tube of Figure 1.
Figures 4, 5, 6, 7 and 8 are isometric views of embodiments of internal
projections for the rotatable breaker tube of Figure 1.
Figures 9a and 9b are schematic isometric views of embodiments of a
rotatable breaker tube.
Figure 9c is a schematic isometric view of a further embodiment of a
rotatable breaker tube.
Figures 9e, 9f and 9g are schematic views of a rotatable breaker tube
showing ore processing within different zones of the rotatable breaker tube of
Figure 9d.
Figures 10, 11 and 12 illustrate embodiments of process fluid sources
within a rotatable breaker tube.
Figures 13 and 14 illustrate further embodiments of process fluid sources.
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Figures 15a, 15b and 15c illustrate embodiments of nozzle arrangements
for a process fluid source.
Figures 16a, 16b and 16c illustrate further embodiments of nozzle
arrangements for a process fluid source.
Figures 17a-e illustrate a further embodiment of a nozzle arrangement for
a process fluid source.
Figures 18 and 19 are partial isometric views of embodiments of an infeed
measurement system and method.
DETAILED DESCRIPTION
In an embodiment, an apparatus is provided for preparing an oil sand ore
slurry by combining oil sand ore and process fluid, the apparatus comprising,
a
tube rotatable about its longitudinal axis, at least a portion of the tube
being
perforated to define a perforated section of the tube; an infeed end of the
tube for
receiving oil sand ore; a discharge end of the tube for discharging reject
material;
a plurality of projecting elements affixed to an interior surface of the tube
and,
adapted to advance and lift received ore as the tube rotates; and, a process
fluid
source for directing process fluid at a portion of the interior surface of the
rotatable tube in the perforated section of the tube, for generation of the
oil sand
ore slurry comprising the process fluid and the oil sand ore received into the
infeed end, less the reject material.
The process fluid source may supply process fluid at differential rates at
different locations within the tube. In an embodiment, the process fluid
source
may supply a greater quantity of process fluid near the infeed end than the
quantity of process fluid supplied near the discharge end.
In an embodiment the process fluid source may comprise a sparge pipe
extending through the tube. The sparge pipe may further comprise a baffle
plate
for dividing the sparge pipe into two sections, an infeed sparge pipe section
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exiting and supplied with process fluid from the infeed end and a discharge
sparge pipe section exiting and supplied with process fluid from the discharge
end.
In an embodiment the process fluid source may comprise a slope sheet for
receiving process fluid at a top portion of the slope sheet and delivering
process
fluid to a portion of the interior surface below a bottom portion of the slope
sheet.
In an embodiment the process fluid source may comprise an infeed supply
pipe positioned at the infeed end of the breaker tube; and, nozzles on the
infeed
supply pipe are arranged to direct process fluid into the breaker tube at a
portion
of the interior surface.
The apparatus may further comprise a discharge supply pipe positioned at
the discharge end of the breaker tube; and, nozzles on the discharge supply
pipe
are arranged to direct process fluid into the breaker tube at a portion of the
interior surface.
In an embodiment, an apparatus is provided for preparing an oil sand ore
slurry by combining oil sand ore and a process fluid, the apparatus
comprising, a
tube rotatable about its longitudinal axis, the tube having a wall thickness
and at
least a section of the tube being perforated such that the perforation extend
through the wall thickness; an infeed end of the tube for receiving oil sand
ore; a
separation zone of the perforated section near the infeed end comprising one
or
more sets of advancing elements affixed to and extending from an interior
surface of the tube, the advancing elements being adapted to advance the
received ore away from the infeed end as the tube rotates; a breaking zone of
the perforated section for receiving advanced ore from the separation zone,
the
breaking zone comprising at least a set of lifting elements affixed to and
extending from an interior surface of the tube, the lifting elements having
contact
faces with smaller angles relative to the longitudinal axis compared to
contact
faces of the advancing elements, and being adapted to lift and drop lump ore;
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and, a discharge end of the tube for receiving oversized material from the
breaking zone as reject material and discharging reject material.
In an embodiment, a method is provided for producing a pumpable oil
sand slurry from mined oil sand ore and a process fluid supplied to an
interior
surface of a rotating breaker tube, the method comprising: depositing the ore
into
an infeed end of the breaker tube, the breaker tube having a wall thickness;
advancing the deposited ore into a separation zone; in the separation zone,
separating a sized fraction of the ore from a lump fraction by passing the
sized
fraction and a portion of the process fluid through perforations that extend
through the wall thickness of the breaker tube and advancing the lump fraction
to
a breaker zone; in the breaker zone, breaking the advanced lump fraction by
lifting and dropping the advanced lump fraction to a bottom portion of the
breaker
tube, separating a further sized fraction by passing the further sized
fraction and
a remainder of the process fluid through perforations that extend through the
wall
thickness of the breaker tube and advancing a reject fraction to a discharge
end;
discharging reject material out the discharge end; and, collecting the passed
sized fraction, the portion of the process fluid, the passed further sized
fraction
and the remainder of the process fluid to produce the oil sand slurry.
In an embodiment, a method is provided for producing a pumpable oil
sand slurry from mined oil sand ore and a process fluid, the method
comprising:
depositing the ore into a separation zone of a breaker tube, the breaker tube
having a wall thickness; directing a supply of the process fluid towards an
interior
surface of the breaker tube; in the separation zone, advancing a lump fraction
of
the ore through the action of a set of advancing elements extending from the
interior surface into a breaking zone, a sized fraction of the ore and a
portion of
the process fluid passing through perforations that extend through the wall
thickness of the breaker tube and being separated from the lump fraction; in
the
breaking zone, breaking the lump fraction of the ore through the action of a
set of
lifting elements extending from the interior surface, and separating a further
sized
fraction by passing the further sized fraction of the ore and a remainder of
the
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process fluid through further perforations that extend through the wall
thickness
of the breaker tube, and advancing a reject fraction of the ore; discharging
the
reject fraction out the discharge end; and collecting the passed sized
fraction, the
portion of the process fluid, the passed further sized fraction and the
remainder
of the process fluid to produce the oil sand slurry.
In an embodiment, a method is provided for producing a pumpable oil
sand slurry from a process fluid and oil sand ore consisting of perforation
sized
material and lump material, the method comprising: depositing the ore into an
infeed end of a breaker tube, the breaker tube having a wall thickness;
directing
a supply of the process fluid towards an interior surface of the breaker tube;
separating a lump fraction from a perforation sized fraction by passing the
perforation sized material through perforations that extend through the wall
thickness of a first section of the breaker tube and advancing the lump
fraction;
breaking a lump fraction of the ore by lifting and dropping the lump fraction
to
create further perforation sized material and simultaneously separating a
further
perforation sized fraction by passing the perforation sized material, the
further
perforation sized material and the process fluid through further perforations
that
extend through the wall thickness of a second section of the breaker tube;
and,
collecting the passed material and the process fluid to produce the oil sand
slurry.
In an embodiment, a method is provided for producing a pumpable oil
sand slurry from a process fluid and oil sand ore consisting of perforation
sized
material and lump material, the method comprising: delivering the ore onto a
feed
conveyor; measuring a quantity of ore carried by the feed conveyor to provide
an
ore quantity measurement; and adjusting the processing of the ore based on the
ore quantity measurement, the processing comprising: depositing the ore into
an
infeed end of a rotating breaker tube; supplying process fluid into the
breaker
tube; separating sized ore material through perforations in the breaker tube
and
breaking lump ore material into further sized material; and, collecting the
passed
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material, the further perforation sized material and the process fluid to
produce
the oil sand slurry.
In an embodiment, a method is provided for producing a pumpable oil
sand slurry from a process fluid and oil sand ore consisting of perforation
sized
material and lump material, the method comprising: depositing the ore into an
infeed end of a breaker tube; directing an adjustable supply of the process
fluid
at differing rates towards an interior surface of the breaker tube to contact
the ore
deposited into the breaker tube; breaking the lump fraction of the ore by
lifting
and dropping the lump fraction creating further perforation sized material;
passing the perforation sized material, the further perforation sized material
and
the process fluid through the perforations in the breaker tube; and,
collecting the
passed material and the process fluid to produce the oil sand slurry.
In an embodiment, a method is provided for producing a pumpable oil
sand slurry from mined oil sand ore and a process fluid supplied to an
interior
surface of a rotating breaker tube, the method comprising: depositing the ore
into
an infeed end of the breaker tube, the breaker tube having a wall thickness
and
having a separation zone and a breaker zone, the separation zone being
upstream of the breaker zone along the breaker tube; advancing the deposited
ore into the separation zone; in the separation zone, separating a sized
fraction
of the ore from a lump fraction by passing the sized fraction and a portion of
the
process fluid through perforations that extend through the wall thickness of
the
breaker tube and advancing the lump fraction to the breaker zone; in the
breaker
zone, breaking the advanced lump fraction by lifting and dropping the advanced
lump fraction to a bottom portion of the breaker tube, separating a further
sized
fraction by passing the further sized fraction and a remainder of the process
fluid
through perforations that extend through the wall thickness of the breaker
tube
and advancing a reject fraction to a discharge end; discharging reject
material
out the discharge end; and collecting the passed sized fraction, the portion
of the
process fluid, the passed further sized fraction and the remainder of the
process
fluid to produce the oil sand slurry.
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In an embodiment, a method is provided for producing a pumpable oil
sand slurry from mined oil sand ore and a process fluid, the method
comprising:
depositing the ore into an infeed end of a breaker tube, the breaker tube
haying a
wall thickness and having a separation zone and a breaking zone; directing a
supply of the process fluid towards an interior surface of the breaker tube;
advancing the deposited ore into the separation zone; in the separation zone,
advancing a lump fraction of the ore through the action of a set of advancing
elements extending from the interior surface into the breaking zone, a sized
fraction of the ore and a portion of the process fluid passing through
perforations
that extend through the wall thickness of the breaker tube and being separated
from the lump fraction; in the breaking zone, receiving ore material
consisting of
the lump fraction from the separation zone, breaking the lump fraction of the
ore
through the action of a set of lifting elements extending from the interior
surface,
separating a further sized fraction by passing the further sized fraction of
the ore
and a remainder of the process fluid through further perforations that extend
through the wall thickness of the breaker tube, and advancing a reject
fraction of
the ore; discharging the reject fraction out a discharge end; and collecting
the
passed sized fraction, the portion of the process fluid, the passed further
sized
fraction and the remainder of the process fluid to produce the oil sand
slurry.
In an embodiment, a method is provided for producing a pumpable oil
sand slurry from a process fluid and oil sand ore consisting of perforation
sized
material and lump material, the method comprising: depositing the ore into an
infeed end of a breaker tube, the breaker tube having a wall thickness;
directing
a supply of the process fluid towards an interior surface of the breaker tube;
separating a lump fraction from the perforation sized material by passing the
perforation sized material through a first arrangement of perforations that
extend
through the wall thickness of a first section of the breaker tube and
advancing the
lump fraction; breaking the lump fraction of the ore by lifting and dropping
the
lump fraction to create further perforation sized material, and simultaneously
separating a further perforation sized fraction by passing the further
perforation
sized material through a second arrangement of perforations that extend
through
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the wall thickness of a second section of the breaker tube, wherein an
upstream
end of the second section of the breaker tube is contiguous with a downstream
end of the first section of the breaker tube for receiving the lump fraction
from the
first section; passing the process fluid through the perforations in the
breaker
tube; and collecting the passed material and the process fluid to produce the
oil
sand slurry.
In an embodiment, an apparatus is provided for preparing an oil sand ore
slurry by combining oil sand ore and process fluid, the apparatus comprising:
a
tube rotatable about a longitudinal axis thereof and having an infeed end for
receiving oil sand ore and a discharge end for discharging reject material, at
least
a portion of the tube being perforated to define a perforated section of the
tube;
and a process fluid source for directing process fluid at a portion of an
interior
surface of the rotatable tube, the process fluid source comprising a sparge
pipe
extending through the tube and being positioned off-center in a direction of
intended rotation of the tube.
In an embodiment, an apparatus is provided for preparing an oil sand ore
slurry by combining oil sand ore and a process fluid, the apparatus comprising
a
tube rotatable about its longitudinal axis with an infeed end for receiving
oil sand
ore and a discharge end for discharging reject material, at least a portion of
the
tube being perforated to define a perforated section of the tube and at least
a
portion of the perforated section comprising lifting elements affixed to and
extending from an interior surface of the tube, the lifting elements
comprising a
combination of multiple sets of neutral lifters for lifting ore and advancer
lifters for
lifting and advancing ore, each set of neutral lifters being delineated by a
set of
advancer lifters.
In an embodiment, an apparatus is provided for preparing an oil sand ore
slurry by combining oil sand ore and a process fluid, the apparatus comprising
a
tube rotatable about its longitudinal axis with an infeed end for receiving
oil sand
ore and a discharge end for discharging reject material, at least a portion of
the
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tube being cylindrical and perforated to define a perforated section of the
tube, the
perforated section comprising a first set of perforations defining a first
open area
and a second set of perforations defining a second open area, the first set of
perforations being closer to the infeed end than the second set of
perforations, and
the first open area being greater than the second open area; and a process
fluid
source for delivering process fluid in order to contact the oil sand ore to
form the
oil sand ore slurry.
In an embodiment, there is provided a method of producing a pumpable oil
sand slurry from a process fluid and oil sand ore, the method comprising:
depositing the ore into an infeed end of a rotating breaker tube;
separating sized ore material through perforations provided in a perforated
section of the breaker tube and breaking lump ore material into further sized
material, wherein the perforated section is cylindrical and comprises a first
set of
perforations defining a first open area and a second set of perforations
defining a
second open area, the first set of perforations being closer to the infeed end
than
the second set of perforations, and the first open area being greater than the
second open area; and
contacting the sized ore material and further sized material that passed
through the perforations with the process fluid to form the oil sand slurry.
In another embodiment, there is provided an apparatus for preparing an oil
sand ore slurry by combining oil sand ore and a process fluid, the apparatus
comprising a tube rotatable about its longitudinal axis with an infeed end for
receiving oil sand ore and a discharge end for discharging reject material, at
least
a portion of the tube being and perforated to define a perforated section of
the
tube, the perforated section comprising a first set of perforations defining a
first
open area and a second set of perforations defining a second open area, the
first
set of perforations being closer to the infeed end than the second set of
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perforations, and the first open area being greater than the second open area;
and
a process fluid source for delivering process fluid in order to contact the
oil sand
ore to form the oil sand ore slurry; wherein the infeed end comprises an
infeed
zone of the tube for receiving the oil sand ore deposited thereon, the infeed
zone
having no perforations and having advancer projections extending inwardly for
advancing the oil sand ore toward the perforated section.
In another embodiment, there is provided an apparatus for preparing an oil
sand ore slurry by combining oil sand ore and a process fluid, the apparatus
comprising a tube rotatable about its longitudinal axis with an infeed end for
receiving oil sand ore and a discharge end for discharging reject material, at
least
a portion of the tube being and perforated to define a perforated section of
the
tube, the perforated section comprising a first set of perforations defining a
first
open area and a second set of perforations defining a second open area, the
first
set of perforations being closer to the infeed end than the second set of
perforations, and the first open area being greater than the second open area;
a
process fluid source for delivering process fluid in order to contact the oil
sand ore
to form the oil sand ore slurry; and an ejection zone at a downstream end of
the
tube, the ejection zone having no perforations and having advancer elements.
In another embodiment, there is provided a method of producing a
pumpable oil sand slurry from a process fluid and oil sand ore, the method
comprising:
depositing the ore into an infeed end of a rotating breaker tube;
separating sized ore material through perforations provided in a perforated
section of the breaker tube and breaking lump ore material into further sized
material, wherein the perforated section comprises a first set of perforations
defining a first open area and a second set of perforations defining a second
open
area, the first set of perforations being closer to the infeed end than the
second set
of perforations, and the first open area being greater than the second open
area;
and
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contacting the sized ore material and further sized material that passed
through the perforations with the process fluid to form the oil sand slurry;
and
wherein the infeed end comprises an infeed zone of the tube for receiving
the oil sand ore deposited thereon, the infeed zone having no perforations and
having advancer projections extending inwardly for advancing the oil sand ore
toward the perforated section.
In another embodiment, there is provided a method of producing a
pumpable oil sand slurry from a process fluid and oil sand ore, the method
comprising:
depositing the ore into an infeed end of a rotating breaker tube;
separating sized ore material through perforations provided in a perforated
section of the breaker tube and breaking lump ore material into further sized
material, wherein the perforated section comprises a first set of perforations
defining a first open area and a second set of perforations defining a second
open
area, the first set of perforations being closer to the infeed end than the
second set
of perforations, and the first open area being greater than the second open
area;
and
contacting the sized ore material and further sized material that passed
through the perforations with the process fluid to form the oil sand slurry;
and
wherein the tube further comprises an ejection zone at a downstream end
of the tube, the ejection zone having no perforations and having advancer
elements.
Figure 1 is an isometric drawing showing rotatable breaker tube 100 with
infeed end 102 and discharge end 104. Breaker tube 100 is shown mounted on
trunion bearings 106 (it will be appreciated that in the configuration of
Figure 1,
there are two further trunion bearings, not shown). Motor 108 is shown with
drive
gear 110 engaged with toothed outer portion 112 of breaker tube 100. Breaker
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tube 100 is driven by motor 108 to rotate in a defined direction of rotation.
In an
alternative drive configuration (not shown), motor 108 may be alternatively
coupled
or geared to drive the breaker tube 100 such as by driving one or more of the
trunion bearings 106.
As shown in Figure 1, breaker tube 100 is preferably divided into a
perforated section 116, with perforations 121 extending through the wall of
the
breaker tube 100, and one or more blind sections 118 having no perforations
121.
Figure 1 illustrates an embodiment where perforated section 116 comprises
curved
plates 120 removably affixed to ribs 122. In the embodiment illustrated,
plates 120
have a generally uniform number of perforations 121 per unit area. In an
alternate
embodiment plates 120 may have varied numbers of perforations 121 in different
sections of the breaker tube 100 as more fully described below.
Breaker tube 100 may be oriented with its longitudinal axis aligned with the
horizontal. Alternatively, the longitudinal axis may be aligned at a slight
declination
toward the discharge end 104. The latter orientation assists in processing and
moving material from the infeed end 102 toward the discharge end 104.
Preferably the perforations 121 comprise passages that are tapered from
a narrower opening at the interior surface 124 of the breaker to a slightly
larger
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opening at the exterior surface of the breaker tube 100 to reduce blinding of
the
perforations 121 when the breaker tube is in use.
The perforation size of this embodiment is preferably selected to screen a
maximum desired size of material passing through breaker tube 100 (perforation
sized material) to downstream processing facilities. Perforation sized
material
generally consists of granular material as well as small lump material able to
fit
through the perforations 121. Due to the erosive nature of oil sand ore,
preferably
the wider opening of a perforation 121 at the exterior of the breaker tube 100
is
sized at manufacture to the intended maximum screening size and the narrow
opening of the perforation 121 at the interior of the breaker tube 100 is
sized
slightly smaller than the intended maximum screening size.
Typically in high volume oil sands operations downstream processing
facilities may require a maximum material size to be limited to a maximum
dimension of about 2"-6". Accordingly, the perforations 121 may be sized to
screen material to the maximum size permitted by the downstream facilities. In
an embodiment the perforations 121 may vary in size up to that maximum
material size. Varying the size of the perforations 121 in different portions
of the
breaker tube 100 provides different throughput and process fluid retention
capacities in each portion.
The perforations 121 may comprise a variety of geometric shapes. For
instance, the perforations 121 may comprise round holes, square holes,
triangular holes or hexagonal holes through the wall of the breaker tube 100.
Generally for ease of manufacturing round or square holes may conveniently be
used. The thickness of the plates 120 and the resistance of perforations 121
to
erosive wear by passage of the abrasive oil sand ore determine the useful life
of
the plates. Typically plates 120 are replaced once or twice year at the change
of
season to balance the cost of downtime for maintenance with the material cost
of
building more robust plates 121.
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Preferably the breaker tube 100 is positioned over a slurry vessel (not
shown) adapted to receive and collect slurry, consisting of sized ore and
process
fluid, that has passed through the perforated section 116 and to feed the
collected slurry to a hydrotransport pump, not shown, adapted to pump oil sand
slurry through a hydrotransport pipeline to a slurry processing facility.
In addition to perforated section 116, Figure 1 shows two blind sections
118, a first such blind section 118 being located at infeed end 102 and the
second blind section located at discharge end 104. As a bearing surface for
trunion bearings 106, blind sections 118 have no perforations 121 such that no
slurry or other material will be permitted to pass through the wall of breaker
tube
100 in such sections. In an alternate embodiment the first blind section 118
near
the infeed end 102 may be extended to provide additional mixing of infeed oil
sand ore and process fluid.
The isometric diagram of Figure 1 shows a limited portion of interior
surface 124. Breaker tube 100 includes a set of internal projections 126 on
interior surface 124, a limited number of which internal projections may be
seen
at infeed end 102 of breaker tube 100 in Figure 1. As will be described in
more
detail with reference to Figure 2 and Figures 7 and 8, internal projections
126
may be adapted to provide for varying effective action in different locations
within
breaker tube 100.
Figure 2 is a schematic diagram of the interior surface 124 of breaker tube
100 showing an arrangement of internal projections 126 on interior surface 124
of breaker tube 100. Figure 2 shows a flattened map of half the interior
surface of
breaker tube 100. A column of internal projections 126 in Figure 2 are
understood to represent half of a complete ring of projections about the
interior of
breaker tube 100 at a particular location along the longitudinal axis.
Typically
each ring will have a consistent pattern of projections 126, though it is not
necessary to have uniform projections 126 within each ring.
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CA 02915349 2015-12-15
The arrangement of differently configured internal projections 126, as
between different groups of rings, provides sections or zones along the
longitudinal axis of breaker tube 100. The differing arrangements and
structures
of internal projections 126 in the different zones of the interior surface 124
result
in a different processing action on the oil sands material in each of the
zones as
the material progresses through breaker tube 100.
Breaker tube 100 preferably comprises at least two zones comprising a
separation zone 152 and a breaking zone 154. The separation zone 152 acts to
separate lump material unable to pass through perforations 121 from
perforation
sized material by allowing perforation sized material to pass through
perforations
121 in the internal surface 124 of the breaker tube 100 while preferentially
advancing lump material toward the discharge end 104.
Internal projections 126 in the separation zone 152 comprise advancing
elements which act to advance infeed material while separating lump material
from perforation sized material either by mixing or tumbling infeed material,
or by
preferentially lifting and advancing lump material out of the infeed material.
Either
type of action acts to improve the effective open area (the unblocked
perforations
121 available to screen perforation sized material). This is achieved by
preventing lump material from occluding perforations 121 and advancing
previously deposited infeed material toward the discharge end 104, thus
providing a clear section of internal surface 124 near the deposition site
available
to receive newly deposited infeed material. Maximizing the available open area
improves throughput in the separation zone 152 and reduces backflow.
The breaking zone 154 acts to lift and drop lump material with breaking
contact, breaking the lump material down into smaller pieces until small
enough
to pass through the perforations 121 in the internal surface 124 of the
breaker
tube 100. The breaking contact may either be against a lower portion of the
internal surface 124 of the breaker tube 100, or against other lump material
situated at the lower portion. A majority of infeed granular material is
preferably
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CA 02915349 2015-12-15
screened out of the breaker tube 100 in the separation zone 152 before
reaching
the breaking zone 154 as granular material tends to absorb impact and reduce
the instances of breaking contact. The breaking zone 154 may include internal
projections 126 adapted to assist in lifting material, as well as internal
projections
126 adapted to advance material.
In the context of a breaker tube 100, the term open area may be used to
describe the sum of the area available for perforation sized material to pass
through the surface of the breaker tube 100. The open area may be changed by
selecting appropriate sizes and numbers of perforations 121 per unit area.
A breaker tube 100 may be optimized by adjusting the open area of each
zone to provide sufficient open area for passage of perforation sized material
in
that zone while maintaining sufficient structural strength for the action
provided
by that zone. In separation zone 152 open area is preferably maximized to
provide increased throughput of perforation sized material as infeed material
is
mainly advanced through feed action of advancing elements. Feed action
provides limited lifting a dropping of material as material tends to remain
concentrated in a localized section of a lower portion of breaker tube 100.
In breaking zone 154 open area may be reduced relative to separation
zone 152 to provide additional structural strength to resist the impact of
lump
material that is lifted and dropped in breaking zone 154 as a significant
portion of
the perforation sized fraction of the infeed material has been separated out
in
separation zone 152 by passing through perforations 121. Breaking zone 154
provides breaking action by lifting and dropping lump material from an upper
portion of breaker tube 100. Since material is lifted up to an upper portion
of
breaker tube 100, material is distributed over a larger area of a section of
internal
surface 124 in the breaking zone 154 than in the separation zone 152.
In general breaker tube 100 may be arranged to allow for greater
structural strength at the cost of less throughput capacity in breaking zone
154
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CA 02915349 2015-12-15
and less structural strength with more opening per unit area in separation
zone
152 to permit maximum throughput of perforation sized material in that zone.
In an embodiment, fewer perforations 121 per unit area may be provided
in breaking zone 154 to provide additional structural support and a greater
number of perforations 121 per unit area provided in separation zone 152 to
provide additional throughput of perforation sized material.
In an embodiment, the perforations 121 are uniformly at the maximum size
and arranged at a maximum number of perforations 121 per unit area throughout
the separation zone 152. In an embodiment the perforations 121 may be
provided at a size less than the maximum size and/or less than a maximum
number of perforations 121 per unit area at an infeed end of separation zone
152
and an increased size and/or increased number of perforations 121 per unit
area
at a discharge end of separation zone 152. Such an embodiment provides for
additional process fluid 344 retention at the deposition site to ensure
sufficient
wetting of infeed ore before separation of perforation sized material from
lump
material.
In an embodiment, the perforations 121 may be provided at a size less
than the maximum size and/or at a number less than the maximum number of
perforations 121 per unit area in the breaking zone 154. In an alternate
embodiment the throughput capacity may decrease (by reducing the number of
perforations 121 per unit area and/or size of the perforations 121) through
the
breaking zone 154 towards the discharge end 104.
In an embodiment illustrated in Figure 2, the separation zone 152 and
breaking zone 154 are complemented by an infeed zone 150 and an ejection
zone 156. lnfeed zone 150 and ejection zone 156 include internal projections
126
which may be configured to include one or more types of advancing elements
such as those shown in Figure 2 as advancing elements 160, 162, 164 (i.e.
ploughs 160 and 162 and paddles 164). Preferably advancing elements 160,
162, 164 extend a distance from the internal surface 124 comparable to the
size
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CA 02915349 2015-12-15
of expected infeed lump material. Preferably each of advancing elements 160,
162, 164 present an elongate surface to the discharge end 104 of breaker tube
100. The elongate surface is arranged at an angle to the longitudinal axis of
breaker tube 100 such that as breaker tube 100 rotates, the rotationally
leading
end of the surface is closer to the infeed end 102 than the rotationally
trailing end
of the surface. Most preferably each of advancing elements 160, 162, 164
present an elongate surface at an angle of about 20-45 relative to the
longitudinal axis to provide a feeding action giving a strong advancement of
material towards discharge end 104 when such material contacts the surface in
rotation.
lnfeed zone 150 is illustrated as having different sized advancing elements
160, 162 for flexibility in manufacture and maintenance. In the embodiment
illustrated, these advancing elements include short ploughs 160 and long
ploughs 162, which are more fully described below. In the embodiment
illustrated, infeed zone 150 corresponds with blind section 118 at the infeed
end
of breaker tube 100 while ejection zone 156 corresponds to blind section 118
at
the discharge end 104 of breaker tube 100. The ploughs 160, 162 may comprise
sections that when affixed in-line provide a combination that effectively
forms a
larger plough body or may be affixed with a gap between sections.
Alternatively,
a continuous plough body may be formed from a single piece of material. It is
generally preferred to create the plough body from multiple ploughs 160, 162
for
ease of manufacturing, installation and maintenance.
Ejection zone 156 may include advancing elements comprising one or
more sets of ploughs 160, 162 or other appropriately arranged and selected
internal projections 126 to assist in advancing reject material out the
discharge
end 104 of the breaker tube 100. Since a majority of the reject material
comprises rock, metal or other hard material that could not be processed in
breaker tube 100, preferably internal projections 126 in ejection zone 156 are
robustly constructed. Preferably internal projections 126 in ejection zone 156
comprise projections such as advancing elements 160, 162, 164 that are
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CA 02915349 2015-12-15
adapted to provide more of an advancing action than a lifting action to reduce
wear caused by lifting and dropping reject material.
In the embodiment of Figure 2, separation zone 152 contains advancing
elements that are configured as paddles 164. Separation zone 152 is shown in
the embodiment of Figure 2 to be located in the first one quarter of the
length of
perforated section 116 of breaker tube 100, though the size of separation zone
152 may be varied. Paddles 164 are configured and arranged to lift and
preferentially advance lump material from infeed material, as is described in
more detail below. Preferably paddles 164 of one ring are arranged such that
their contact surfaces are aligned with paddles 164 of adjacent rings.
In an alternate embodiment, separation zone 152 may contain ploughs
160, 162. The ploughs 160, 162 in separation zone 152 advance and mix infeed
material, separating lump material as the perforation sized material falls
through
the perforations 121 in the internal surface 124 of the breaker tube 100.
Ploughs
160, 162 in separation zone 152 lift and advance material while advancing the
material into the breaker tube 100. Granular and perforation sized material
will
tend to roll/wash off the ploughs 160, 162 at a lower point of rotation than
lump
material, providing a separation action that tumbles and advances infeed
material, preferentially screening perforation sized material through the
perforations 121 and advancing lump material to the breaking zone 154.
In the embodiment of Figure 2, the balance of perforated section 116 in
breaker tube 100 forms breaking zone 154. In the illustrated embodiment of
breaking zone 154, internal projections 126 comprise lifting elements 166, 168
and consist of a combination of advancer lifters 166 and neutral lifters 168.
Advancer lifters 166 provide a lifting action with some advancement to assist
in
urging material toward the discharge end 104. Neutral lifters 168 provide a
lifting
action to lift and drop lump material. The embodiment of Figure 2 comprises
three repeating sets of advancer lifter 166 and neutral lifter 168
combinations.
Each set comprises a first ring of advancer lifters 166, followed by three
rings of
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CA 02915349 2015-12-15
neutral lifters 168. The number and combination of advancer lifters 166 and
neutral lifters 168 may vary depending upon the requirements of throughput and
breaking action required.
Figures 3a, 3b, 3c, 3d illustrate alternate configurations of perforations 121
through a portion of a plate 120. In the embodiments illustrated the
perforations
121 are of consistent size and concentration within the portion illustrated.
In an
alternate to the embodiment to Figure 3d (not shown), circular perforations
121
may be staggered to provide more perforations 121 per unit area.
The embodiments illustrated and described below are for a breaker tube
100 aligned with a horizontal longitudinal axis. In embodiments where breaker
tube 100 is aligned with a longitudinal axis on a decline toward the discharge
end
104, a reduced angle of the leading face of each of the internal projections
126
relative to the longitudinal axis may be provided.
The embodiments illustrated are for exemplary internal projections 126
and specific location of attachment points, reinforcement or geometry are not
intended to be limiting. The internal projections 126 are described herein as
being adapted to provide a leading contact face that lifts, advances or lifts
and
advances oil sand toward the discharge end 104 as the breaker tube 100 rotates
in its intended direction. The angle of a contact face is described with
reference
to the longitudinal axis of the breaker. For an advancing element, as breaker
tube
100 rotates, the rotationally leading end of the contact surface is closer to
the
infeed end 102 than the rotationally trailing end of the surface such that the
leading end of the face contacts material first during rotation, urging the
contacted material toward the discharge end 104. The angle of a contact face
affects a balance between lifting action and advancing action with an angle of
0
providing primarily lifting action, an angle close to 450 providing
significant
advancing action. Advancing elements 160, 162, 164 typically comprise elements
with contact faces aligned at 30 -45 to provide desired advancing action.
Lifting
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CA 02915349 2015-12-15
elements 166, 168 typically comprise elements with contact faces aligned at 0 -
25 to provide desired a lifting or lifting and advancing action.
In a preferred embodiment, infeed zone 150 comprises advancing
elements 160, 162, 164 with contact faces aligned with the longitudinal axis
at
about 45 to provide strong advancement of infeed material from the deposition
point through the separation zone 152.
In a preferred embodiment, separation zone 152 comprises advancing
elements 160, 162, 164 with contact faces aligned with the longitudinal axis
at
about 45 to provide strong advancement of infeed material while screening
perforation sized material through perforations 121.
In a preferred embodiment, breaking zone 154 comprises advancer lifters
168 with contact faces aligned at about 5 -20 to provide lifting action with
some
advancement to maintain flow of material toward the discharge end 104 and
away from the infeed end 102. In a preferred embodiment, breaking zone 154
comprising neutral lifters 166 with contact faces aligned at about 0 .
It will be understood by those skilled in the art that the angular references
provided will be subject to operating conditions of the rotary breaker.
In a preferred embodiment, discharge zone 156 comprises advancing
elements 160, 162, 164 with contact faces aligned at about 45 to provide
desired primarily advancing action.
Figure 4 illustrates an embodiment of a short plough 160 that may be fixed
to interior surface 124 in the locations shown in the schematic representation
of
Figure 2. Figure 4 shows connector plates 302 and 304 used to bolt short
plough
160 to interior surface 124. Short plough 160 is adapted to present face 161
at
an angle to oil sand material contacted as the breaker tube 100 rotates about
its
longitudinal axis. As described above, the angle is selected such that when
the
breaker tube 100 rotates, oil sand material in the breaker is first contacted
by the
rotationally leading end of face 161 closer to the infeed end 102, urging the
oil
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CA 02915349 2015-12-15
sand material towards discharge end 104 so as to provide an advancement
action on in infeed material.
Long plough 162 (not shown) has the same overall configuration as short
plough 160 but has a longer length than short plough 160 and may include
further connection points to secure long plough 162 along its length to the
interior
surface 124. Combinations of short ploughs 160 and long ploughs 162 are
preferably used in place of larger ploughs to allow repair and replacement of
ploughs that may be damaged without removal of large plough elements that
would be otherwise required.
In the embodiment illustrated the attachment points for internal projections
126 are oriented in-line with the longitudinal axis of breaker tube 100. In
alternate
embodiments (not shown) the attachment points may be oriented at an angle to
the longitudinal axis and accordingly the arrangement of the bolt holes on
internal
projections 126 may vary from the embodiments illustrated herein.
Figure 5 is an isometric illustration of an embodiment of paddle 164. In the
embodiment illustrated paddle 164 comprises upstanding member 316 and base
member 317. Base member 317 is arranged to provide a secure connection point
for securing paddle 164 to breaker tube 100 (for instance with bolts or
welding).
Preferably, paddle 164 presents face 308 to provide preferential lifting and
advancement of lump material from the infeed material. In an embodiment
paddle 164 presents face 308 at an angle of 30 -45 to the longitudinal axis.
Figure 6 is an isometric drawing of an embodiment of neutral lifter 168. In
the embodiment illustrated neutral lifter 168 comprises upstanding member 313
and base member 311. Base member 311 is arranged to provide a secure
connection point for neutral lifter 168 to breaker tube 100 (for instance with
bolts
or welding). Neutral lifter 168 is adapted to present face 310 at a neutral
angle,
substantially parallel to the longitudinal axis of the breaker tube 100 when
installed (for a horizontally aligned breaker tube 100). The neutral angle of
face
310 provides a lifting action to material located at a bottom portion of
breaker
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CA 02915349 2015-12-15
tube 100 as it rotates about its longitudinal axis. Further, face 310 may
include
protruding sections 312 to resist wear and prevent lifted material from
prematurely falling off face 310 as the material is lifted with the rotation
of
breaker tube 100.
The length and width of face 310 may be selected to provide lifting action
to lumps of a predetermined size and neutral lifters 168 may be characterized
as
large or small based upon the size of face 310 and how high it extends from
interior surface 124. Larger lumps tend to roll off relatively small neutral
lifters
168 at a lower portion of breaker tube 100. Larger neutral lifters 168 tend to
cause more wear to interior surface 124 from impact as they lift all lump
material,
including large lump material, to a top portion of breaker tube 100.
Preferably
neutral lifters 168 are minimally sized to the lump material to provide
sufficient
breaking at a given feed rate and quality of infeed ore. Generally neutral
lifters
168 will be sized smaller than the larger lump material near the infeed end
102 to
minimize wear on the plates 120.
Figure 7 is an isometric drawing of an embodiment of advancer lifter 166.
In the embodiment illustrated advancer lifter 166 comprises upstanding member
306 and base member 315. Base member 315 is arranged to provide a secure
connection point for advancer lifter 166 to breaker tube 100 (for instance
with
bolts or welding). Advancer lifter 166 is adapted to present face 314 at an
angle
to the longitudinal axis of the breaker tube 100 when installed. Advancer
lifter
166 is installed on the interior surface 124 of the breaker tube 100 to
present
face 314 at an angle to oil sand material contacted as the breaker tube 100
rotates about its longitudinal axis. Typically advancer lifters 166 may be
arranged
to present face 314 at an angle less than about 20 but greater than about 5
to
provide a combination of advancing and lifting action. At higher infeed rates
advancer lifters 166 near the infeed end 102 may be presented with a larger
angle in the range to provide relatively greater advancing action. Advancer
lifters
166 in the middle of the breaking zone 154 are typically provided with a
smaller
angle, for example, about 15 to provide primarily lifting action with some
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CA 02915349 2015-12-15
advancing action. Advancer lifters 166 in this location preferably have a
smaller
contact angle to increase the dwell time of material in the breaking zone 154.
Further, face 314 has protruding sections 316 (similar to those found on face
310) to resist erosion and prevent lifted material from prematurely falling
off face
314 as the material is lifted with the rotation of breaker tube 100.
Figure 8 is an isometric drawing showing an embodiment of an internal
projection 126 having a larger contact surface 318. In the embodiment of
Figure
8 the internal projection comprises an advancer lifter 167. In the embodiment
illustrated advancer lifter 167 comprises upstanding member 321 and base
member 319. Base member 319 is arranged to provide a secure connection point
for advancer lifter 167 to breaker tube 100 (for instance with bolts or
welding).
Advancer lifter 167 is adapted to present face 318 at an angle to the
longitudinal
axis of the breaker tube 100 when installed.
As will be appreciated, factors such as strength, weight, face size and
orientation, and resistance to wear are considered in selecting the structural
arrangements of the various internal projections 126. Although Figures 4 to 8
illustrate example ploughs, paddles and lifters, other structures may be used
to
provide internal projections to act on oil sand material as rotation of
breaker tube
100 occurs, in accordance with this description.
Figure 9a is an isometric schematic diagram showing breaker tube 100
and its relationship with a process line for processing mined oil sand ore
into a
pumpable oil sand slurry (note that Figure 9 is a reverse view from the view
of
breaker tube 100 in Figure 1). A conveyor 320 is positioned with its discharge
end 322 located to discharge conveyed oil sand ore into breaker tube 100. A
slope sheet 324 is positioned below discharge end 322 extending from conveyor
320 into breaker tube 100 to collect and direct granular material and process
fluid
344 that may otherwise fall short of the intended deposition point.
In the embodiment illustrated in Figure 9a slope sheet 324 comprises a
collector for collecting process fluid and fine granular material and
directing them
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CA 02915349 2015-12-15
into breaker tube 100. Also as illustrated, slope sheet 324 may comprise a
process fluid source supplying process fluid 344 directed down a top surface
of
slope sheet 324 to provide additional process fluid 344 delivery means at the
deposition point downstream of discharge end 322 of the conveyor 320.
Figure 9b illustrates an alternate embodiment where conveyor 320 is
positioned to extend into breaker tube 100 with no slope sheet 324. Preferably
in
this embodiment a scraper plate 325 is provided under conveyor 320 to remove
any remaining oil sand ore.
Slope sheet 324 may be a flat sheet as illustrated in Figure 9a, or
alternatively as illustrated in Figure 9c may include side walls 327 to
provide a
shallow trough for delivering oil sand ore 326. In an alternate embodiment
(not
shown), the slope sheet 324 comprises a V-shaped trough for delivering oil
sand
ore 326.
In the embodiment illustrated in Figures 9a, 9b and 9c, sparge pipe 340 is
suspended within and extends through breaker tube 100. As will be described
below, other arrangements provide alternate means to deliver process fluid 344
that do not require a sparge pipe 340. Sparge pipe 340 has nozzles 342
disposed along its length for delivery of process fluid 344 directed towards a
portion of the interior surface 124 of breaker tube 100 to provide for mixing
of
process fluid with oil sand ore material in the breaker tube 100 material (not
shown in Figures 9a, 9b, 9c).
Figures 9d, 9e, 9f, 9g are illustrations schematically representing oil sand
ore 345 and 346 within different zones 150, 152, 154 of breaker tube 100. In
Figures 9e, 9f, 9g, oil sand ore material is shown schematically as sized
material
345 (i.e. oil sand ore material that has dimensions to permit passage through
openings of the dimensions of perforations 121) and lump material 346 (i.e.
material with dimensions that preclude such passage). In the schematic cross
section of Figure 9g (referencing a ring in zone 150, viewed towards discharge
end 104), material 345 and 346 are show as deposited into infeed zone 150. The
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CA 02915349 2015-12-15
material is predominantly located at a lower or bottom portion of breaker tube
100. Alternatively, as described above, oil sand ore could be deposited
directly
into separation zone 152, in which case the portion of separation zone 152 at
the
deposition site would exhibit a similar oil sand ore distribution. Figure 9f
schematically represents a ring of breaker tube 100 in separation zone 152
(viewed towards discharge end 104). Figure 9f shows material 345 and 346
distributed across a bottom portion of breaker tube 100 and, relative to the
distribution in Figure 9g, slightly raised up but still within a lower portion
of the
lifting wall of breaker tube 100. Figure 9e shows, schematically, a ring in
breaking
zone 154 in which much of the perforation sized material 345 has passed
through perforations 121 leaving predominantly lump material 346 remaining in
breaking zone 154 where such material is lifted for breaking deposition into
smaller sized material 346 as is suggested in Figure 9e. As is described
further,
below, water 344 is shown as differentially distributed in the schematic
representations of Figures 9e, 9f, 9g.
Figure 10 is a schematic cross-section drawing showing breaker tube 100
and trunion bearings 106. Representative neutral lifter 168 is shown with a
lump
346 being lifted in a clockwise direction. As will be appreciated, the lump
346 will
tend to disengage from neutral lifter 168 and follow a trajectory that is
determined
by the original rotational motion of breaker tube 100 and by gravity.
Preferably, sparge pipe 340 is positioned in a top portion of breaker tube
100. Locating sparge pipe 340 as shown in Figure 10, positioned near a top
portion of breaker tube 100 and offset from the vertical center line, provides
additional clearance between sparge pipe 340 and the tumbling ore trajectory
as,
for example, lump 346 falls off neutral lifter 168. This will reduce the
likelihood
that ore lump material 346 will impact sparge pipe 340 when breaker tube 100
is
operated (and particularly at higher rotational speeds).
To further avoid damage to sparge pipe 340 from the impact from tumbling
ore, there is provided, as illustrated in the schematic cross section of
Figures 11
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CA 02915349 2015-12-15
=
and 12, protection for the sparge pipe in the form of a protective shell 350
enclosing sparge pipe 340. In the embodiment of Figure 11, nozzle 342 may
extend beyond protective shell 350. Protective shell 350 may also provide
structural support for supporting sparge pipe 340 along its length within
breaker
tube 100. An alternative protective arrangement is illustrated in the
schematic
cross-section of Figure 12, in which sparge pipe 340 and nozzle 342 are both
enclosed by protective shell 350. A further alternate embodiment of protective
shell 350, sparge pipe 340 and nozzles 342 is illustrated in Figure 17b.
Returning to Figures 9a, 9b and 9c, baffle plate 360 preferably divides
sparge pipe 340 into two sections: an infeed section supplied with process
fluid
344 from the infeed end 102 of breaker tube 100 and a discharge section
supplied with process fluid 344 from a discharge end 104 of breaker tube 100.
Such a division permits differential delivery of process fluid 344 to
different zones
of breaker tube 100. Further, the embodiment of Figures 9a, 9b and 9c may be
combined with varied number and diameter of nozzles 342 to allow fine-tuning
of
the distribution of process fluid 344 in each zone (an example of which is
shown
in Figures 9e, 9f and 9g). As an alternative to use of a baffle plate 360 in a
single
sparge pipe 340, separate supply lines may be provided for each section.
The schematic drawing of Figure 13 shows an alternative arrangement of
pipes and nozzles for delivery of process fluid 344. In Figure 13, conveyor
320 is
shown arranged such that discharge end 322 is located outside breaker tube 100
near infeed end 102. This arrangement permits slope sheet 324 to be located
partly within breaker tube 100 and partly outside the infeed end 102 of the
breaker tube 100. As a result, process fluid 344 may be sprayed onto ore 326
after it progresses off the discharge end 322 of conveyor 320 while it travels
down slope sheet 324. Process fluid 344 is shown being delivered by exterior
supply pipe 370. Supply pipe 370 comprises nozzles 342 arranged to spray
process fluid 344 onto slope sheet 324. Additional process fluid source(s) may
in
combination with supply pipe 370 supply process fluid 344 to an upper surface
of
slope sheet 324, such as the embodiments illustrated in Figures 9a, 9b and 9c.
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CA 02915349 2015-12-15
lnfeed supply pipe 372, with associated nozzles 342, is located in
proximity to infeed end 120 to deliver process fluid 344 into breaker tube 100
directed at interior surface 124. As illustrated, infeed supply pipe 372 and
its
associated nozzles 342 are positioned to avoid the mined oil sand ore 326 flow
as it enters breaker tube 100. Discharge supply pipe 374, with associated
nozzles 342, is located in proximity to discharge end 104 to deliver process
fluid
344 into breaker tube 100 directed at interior surface 124. In the
configuration of
Figure 13, discharge supply pipe 374 is arranged to avoid the material that is
discharged from breaker tube 100.
Infeed supply pipe 372 and discharge supply pipe 374 are depicted as
comprising different exemplary pipe configurations, an inverted U-shaped
section
and a generally semi-circular section respectively, however both elements
could
comprise either of the exemplary configurations.
Figure 14 is a cross-sectional schematic drawing of the breaker tube 100
with infeed supply pipe 372, discharge supply pipe 374 and slope sheet 324
comprising side walls 327. Figure 14 shows nozzles 342 oriented to direct
process fluid 344 throughout a lower portion of perforated section 116 of
breaker
tube 100. A variation of this embodiment includes distributing the process
fluid
344 differentially along the perforated section 107, wherein more process
fluid
344 is distributed at the infeed end 102 of breaker tube 100.
In an embodiment (not shown), only the infeed supply pipe 372 or the
discharge supply pipe 374 may be provided, alone or in combination with an
alternate process fluid source such as slope sheet 324 or sparge pipe 340.
Process fluid 344 may be uniformly distributed within breaker tube 100 or,
preferably, may be differentially distributed within breaker tube 100, as
illustrated
in the exemplary embodiments of Figures 15a, 15b, 15c, 16a, 16b and 16c.
Each of Figures 15a, 15b, 15c, 16a, 16b and 16c show breaker tube 100
in schematic cross-section having sparge pipe 340 with nozzles 342 having
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CA 02915349 2015-12-15
alternative dimensions and locations for delivery of process fluid 344. Each
of the
arrangements in Figures 15a, 15b, 15c, 16a, 16b and 16c shows variation in
delivery of process fluid 344
In general, the infeed section of the sparge pipe 340 may supply a greater
fraction of the total volume of process fluid 344 supplied to the breaker tube
100.
In a typical embodiment approximately 70-80% of the total volume of process
fluid 344 may be supplied by the infeed section of sparge pipe 340 to improve
oil
sand throughput capacity near the infeed end 102.
In general, a first quantity of process fluid may be supplied to assist in the
separation of perforation sized ore from lump ore and a second quantity of
process fluid may be supplied to assist in the breaking of lump ore. The
supply of
process fluid 344 acts to wet ore and flush perforation sized ore through
perforations. In the breaking zone 154, process fluid 344 may act to assist in
the
breaking action by flushing perforation sized ore through perforations and to
wet
ore newly exposed during the breaking action.
As illustrated in Figure 15a, the infeed section 347 of sparge pipe 340 near
the infeed end 102 of breaker tube 100 may comprise a greater concentration of
nozzles 342 than the discharge section 348 of sparge pipe 340 near the
discharge end 104. Alternatively, as illustrated in Figure 15b, nozzles 343
disposed along the infeed section 347 may be larger than those disposed near
the discharge section 348 of the sparge pipe 340 such that each larger nozzle
343 supplies more process fluid 344 than a corresponding smaller nozzle 342 in
the discharge section 348. Figure 15c illustrates an embodiment were the
differential delivery of process fluid 344 is achieved by differing the supply
flow
rate between the two sections while the nozzle size and quantity is similar as
between the two sections. In the embodiment illustrated a greater proportion
of
process fluid 344 is delivered to the infeed section 347, flooding the
separation
section 348 with process fluid 344. Alternatively a combination of
differential
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CA 02915349 2015-12-15
supply flow rate and nozzle size, or quantity may be employed to achieve the
differing supply flow rate between the two sections.
Figure 16a illustrates an embodiment similar to Figure 15a, with the
exception that the endmost nozzles 345 are directed to distribute the majority
of
their flow towards a middle portion of breaker tube 100. Figure 16b
illustrates an
embodiment for supplying varied flow within a section of sparge pipe 340. In
the
embodiment of Figure 16b, a central portion 349 of the discharge section 348
near baffle plate 360 has a greater concentration of nozzles 342 to provide
increased supply of process fluid 344 in the near a middle portion of breaker
tube
100 and progressively less process fluid 344 towards the discharge end 104.
The
embodiment of Figure 16b is further illustrated in Figure 17.
Figure 16c illustrates an embodiment wherein the endmost nozzles 345
are directed to distribute the majority of their flow into a middle portion of
breaker
tube 100 and a greater concentration of nozzles 342 are located at an oil sand
deposition point in breaker tube 100 to supply a higher concentration of
process
fluid 344 at the oil sand deposition point near the infeed end 102.
In a further illustration of the embodiment of Figure 16b, Figure 17a
illustrates a section of sparge pipe 340 near baffle plate 360. The infeed
section
347 portion of the sparge pipe 340 at the infeed side of baffle plate 360
comprises a greater concentration of nozzles 342 than the central portion 349
of
the discharge section 348 of the sparge pipe 340 at the discharge side of
baffle
plate 360. In the embodiment illustrated alternate nozzles 342 are offset to
provide alternating process fluid 344 trajectories. For instance, one nozzle
may
be directed on the lifting wall of breaker tube 100 and the next nozzle on the
bottom portion of the breaker tube 100. Alternating nozzle trajectories
assists in
providing even coverage of process fluid 344 to assist in washing the
perforation
sized material resulting from broken lumps through the perforations 121.
As described above, process fluid 344 is added to mined oil sand ore to
form a slurry. It is preferable to match the supply of process fluid 344 to
specific
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zones within breaker tube 100. Infeed zone 150 is intended to feed mined ore
from the infeed end 102 into the body of breaker tube 100 to clear the infeed
end
102 to make space for additional mined oil sand ore that is continuously
supplied.
The delivery of process fluid 344 in the infeed zone 150 is intended to
provide
wetting of the ore. At the deposition site, the oil sand ore is mainly located
at a
bottom portion of the breaker tube 100 offset slightly in the direction of
rotation.
Accordingly, the supply of process fluid 344 in this zone is preferably
directed to
cover the approximately one quarter to one half of the breaker tube 100 wall
area
where a substantial portion of infeed material is located as illustrated in
Figure
9g. In an embodiment jet nozzles are used to supply process fluid 344 to
infeed
zone 150 and separation zone 152 to impart a jet action onto the ore as it
tumbles for efficient wetting and mixing of the ore. In separation zone 152,
the jet
action also assists in clearing the perforations 121 in this high volume
portion of
breaker tube 100.
Figures 17b-17e are simplified cross-section illustrations through breaker
tube 100 at various locations along its length showing an embodiment of sparge
pipe 340 providing differential delivery of process fluid 344. In the
embodiment of
Figures 17b-17e, pairs of alternating nozzles 342 are used to provide varied
distribution of process fluid 344. In an embodiment the nozzles may be located
at
different offsets about the sparge pipe 340 to provide alternate spray
trajectories.
Figure 17b illustrates a cross-section taken near the feed end 102 where
process fluid 344 is directed at a bottom portion of breaker tube 100,
concentrated in an area where oil sand is deposited. Figure 17c illustrates a
cross-section taken in the separation zone 152 where process fluid 344 is
directed at a bottom portion of breaker tube 100, extending somewhat up the
lifting wall. Figure 17d illustrates a cross-section taken in the breaking
zone 154
where process fluid 344 is directed at a bottom portion of breaker tube 100
and
extends up the lifting wall. Figure 17e illustrates a cross-section taken near
the
ejection zone 156 where process fluid 344 is directed in a wide angle wash.
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CA 02915349 2015-12-15
Figures 9e-9g illustrate the application of process fluid 344 in combination
with ore composition in different zones within the breaker tube 100. Figure 9e
illustrates a schematic cross-section in the breaking zone 154 showing process
fluid 344 directed across the bottom portion of the breaker tube 100 as well
as
across the lifting wall of breaker tube 100 to contact lump material as it is
lifted. In
Figure 9f, in an infeed end of the separation zone 152, oil sand ore material
is
shown shifted somewhat in the direction of rotation up the lifting wall of the
breaker tube 100. The process fluid 344 is directed across an increased
portion
of breaker tube 100, concentrated where oil sand is distributed. Figure 9g
illustrates a cross-section near the deposition site. Preferably process fluid
344 is
directed in a concentrated spray at a lower portion of the breaker tube 100 at
the
deposition site to assist in wetting the ore and flushing perforation sized
ore
through the perforations 121. A wide angle wash of process fluid 344 (shown in
Figure 17e) may be used near the discharge end 104 to wash away any
remaining bitumen and granular material.
The density of a resulting oil sand slurry is preferably adjusted by
controlling the addition of process fluid 344 inside breaker tube 100.
Supplying
process fluid 344 for the slurry into the breaker tube 100, as opposed to
providing
makeup fluid to a slurry vessel capturing the output from breaker tube 100,
provides for a more consistent slurry as well as additional aeration of the
slurry
which assists downstream slurry conditioning and processing.
Figure 18 illustrates in embodiment of a portion of a conveyor 320 with
mined oil sand ore 326 being conveyed towards a breaker tube 100. Level
sensor 400, such as a radar or laser sensor, is shown in the embodiment of
Figure 18, arranged relative to conveyor 320 so as to permit a scan to be
performed to measure or detect the distance between level sensor 400 and the
top of mined oil sand ore 326 being conveyed to determine a height of the
mined
oil sand ore 326 on conveyor 320. By sampling the height level with the feed
rate
of conveyor 320 an estimate of oil sand infeed rate may be determined. A
further
alternative to level sensor 400 is shown in Figure 19 where level sensor 402
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CA 02915349 2015-12-15
comprises horizontally arranged sensing means to measure the distance
between a height of ore 326 travelling below level sensor 402 from which an
estimate of ore height may be calculated.
Regarding the process carried out by the level sensor 400 or 402 in the
embodiment of Figures 18 and 19, granulated ore typically presents a
consistent
level to weight measurement. Reduced quantities of granulated ore typically
presents a decrease in the absolute values of the level measurement and the
weight measurement with a relatively consistent level to weight measurement.
Ore containing large lump material will typically present a discrepancy in the
level
to weight measurement as compared with the absolute value of the weight
measurement. Where a discrepancy exists between the level to weight
measurement and the absolute value of the weight measurement and/or level
measurement, a processor unit may slow, or accelerate, an apron feed conveyor
delivering ore to conveyor 320 for a period of time, such that breaker tube
100
may receive a relatively consistent ore feed for processing despite variation
in
consistency of ore feed along the conveyor 320.
Conveyor 320 may also be equipped with a scale/weightometer (not
shown) in addition to, or as an alternative to, level sensor 400. The
weightometer
provides a continuous weight measurement which may be used to determine the
infeed rate of oil sand material. The weightometer may be employed to control
the infeed rate by adjusting the feed of oil sand ore onto conveyor 320, for
instance by adjusting the feed rate of an apron feeder fed by a hopper.
Where a combination of weightometer and level sensor 400 is employed,
level sensor 400 measures the height of the incoming ore feed 326 being
carried
by conveyor 320 and the scale measures the weight of the ore travelling along
the conveyor 320. The two measurements may be compared to render a more
accurate estimate of infeed rate.
In operation, the process capacity of a breaker tube 100 for mined oil sand
ore 326 is related to the amount of material that is passed from the interior
of
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CA 02915349 2015-12-15
breaker tube 100, through perforations 121 near the infeed end 102 of the
breaker. As mined oil sand ore is subject to motion and impact within rotating
breaker tube 100, sized material is obtained. Increasing the proportion of
perforation sized material that passes through perforations 121 closer to
infeed
end 102 reduces the likelihood of material backflow out infeed end 102,
reduces
the amount of reject material ejected from discharge end 104 and increases the
process capacity of breaker tube 100.
Further, the process capacity of a rotary breaker for mined oil sand ore
326 may be increased if sized material is separated from lump material closer
to
infeed end 102. If ore lumps remain unseparated from perforation sized
material,
the lumps have a greater chance of occluding perforations 121 in the internal
surface 124 of breaker 100 and reducing the effective perforated area
available
to allow passage of the perforation sized material. Ore lumps may be separated
from sized material near the internal surface 124 either by preferentially
lifting
and advancing lump material, for instance by the action of paddles 164, or by
mixing or tumbling infeed material, for instance by the action of ploughs 160,
162.
Efficient breaking of ore lumps, especially winter ore lumps, is enhanced if
the ore lumps are lifted and dropped by the motion of breaker tube 100 such
that
the location at which the ore lumps land at a bottom portion of internal
surface
124 of breaker tube 100 has a minimal amount of granular material so as to
improve the chances of breaking contact with either surface 124 or other lump
material. Accordingly, separation of perforation sized material, consisting of
granular material and small lumps, from the infeed ore near the infeed end 102
enhances the process capacity of the breaker tube 100.
Aspects of the breaker tube 100 embodiments illustrated in the Figures,
and described above, increase the efficiency of breaking of mined oil sands
ore
326 within breaker tube 100, as the breaker tube 100 operates to produce a
slurry. In one aspect, the design and arrangement of internal projections 126
on
interior surface 124 as described will assist in the efficiency of the rotary
breaker
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CA 02915349 2015-12-15
used for producing a slurry of mined oil sand ore. As indicated, the
configuration
and placement of such internal projections 126 define zones or sections within
breaker tube 100.
Returning to the embodiment illustrated in Figure 2, breaking zone 154
comprises multiple lifting zones shown as zones D1, D2, D3 in the figure. Each
such lifting zone is preceded by an advancing zone Cl, C2, 03. Advancing zone
Cl contains advancer lifters 166 that lift and advance the ore material into
lifting
zone Dl. Lifting zone D1 contains neutral lifters 168 that lift lumps with the
rotation of breaker tube 100 to drop the lumps onto the bottom portion of the
breaker tube 100 so as to break such lumps into smaller pieces and granular
material. This type of lifting and breaking action is illustrated in more
detail in
Figure 10. Preferably, and as shown in Figure 2, in lifting zones D1, D2, 03,
the
neutral lifters 168 in each row or ring are offset from those in the adjacent
row or
ring so as to permit sized material to remain at the bottom portion of breaker
tube
100 for passage through perforations 121 while preferentially lifting the lump
material,
The selective lifting movement of material in breaking zone 154, such that
lump material tends to be lifted while sized material tends not to be lifted
to the
same degree, increases the effective open (perforated) area available for
passage of perforation sized material and further separates lump material from
sized material. As is described in more detail below with reference to the
delivery
of process fluid 344, as ore material advances down the length of breaker tube
100 towards discharge end 104, sized material is washed through the
perforations 121, clearing breaker tube 100 for contact with lump material
that is
lifted and dropped to the bottom of breaker tube 100 in the lifting zones D1,
02,
03. It is preferred to lift and drop lump material directly onto the interior
surface
124 of breaker tube 100 or other lump material rather than onto granular
material
as granular material tends to absorb the impact and reduce the breaking action
imparted on the lump material.
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CA 02915349 2015-12-15
Improved efficiency in the passage of perforation sized material through
perforations 121 in breaker tube 100 reduces the amount of process fluid 344
required to operate breaker tube 100 at higher infeed rates. For higher infeed
rates, an extension of separation zone 152 similar to that shown in Figure 2
may
be provided. Extending separation zone 152 increases the capacity of breaker
tube 100 for preferentially separating sized material from infeed material
through
perforations 121 before lifting and dropping lump material.
Advancing zone 02 contains advancer lifters 166 that are configured and
arranged to lift and advance material in zone 02 into lifting zone D2.
Typically
material will remain in lifting zone D1 until either random tumbling causes it
to
pass through to the advancing zone C2 advancers 166, or additional infeed
material is advanced through advancing zone Cl into lifting zone D1,
displacing
the material already in lifting zone Dl.
The use of multiple lifting zones D1, D2, D3 each delineated by an
advancing zone Cl, 02, 03 is preferable over a single large lifting zone with
no
advancing zone Cl, 02, 03 to ensure material progresses toward discharge end
104. The inclusion of a breaking zone 154 including advancing zones 01, 02, 03
containing rings of advancer lifters 166 provides an advantage in maintaining
ore
progression through breaker tube 100, irrespective of the infeed rate of new
material. This allows breaker tube 100 to operate efficiently with both high
infeed
rates as well as variation in the infeed quality and rate. Where the
longitudinal
axis of breaker tube 100 is aligned on a decline with respect to the
horizontal, it
may not be necessary to include rings of advancer lifters 168 as the
orientation of
a declined breaker tube 100 will cause material to progress toward discharge
end
104.
Lifting zone D2 contains neutral lifters 168 that lift lumps with the rotation
of breaker tube 100 so as to drop the lumps with breaking contact onto the
bottom portion of breaker tube 100, or other lump material located there, and
thereby to break the lumps into smaller pieces. In Figure 2, neutral lifters
168 in
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CA 02915349 2015-12-15
lifting zone D2 are shown as being arranged in a similar pattern to those in
zone
Dl. This arrangement in zone D2 will serve to give a dwell time for ore
material in
that zone roughly equivalent to the dwell time in zone Dl. Alternatively,
neutral
lifters 168 may be arranged in a different pattern to increase the dwell time
of
material that has been advanced into lifting zone D2. One way to achieve such
a
longer dwell time is to reduce the number of such neutral lifters 168 in zone
D2.
In one arrangement, neutral lifters 168 in lifting zone D1 are arranged to
allow a dwell time as shown by their arrangement in Figure 2, whereas neutral
lifters 168 in lifting zone 02 are fewer in number and therefore have a longer
dwell time (this arrangement is not shown). In the arrangement shown in Figure
2
for zone D1, lump material is intended to be preferentially lifted relative to
granular material and is thereby eventually advanced into lifting zone D2,
thereby
clearing lifting zone D1 of lump material. It may also be useful to
preferentially lift
and advance lump material out of the granular material where higher infeed
rates
cause granular material to pass through from the separation zone 152 into
lifting
zone Dl. In an embodiment, what is shown in Figure 2 as lifting zone D1 may
include one or more advancer lifters 166 or paddles 164 to impart a more
aggressive advancing action to urge lump material toward discharge end 104.
Generally, however, it is preferred to provide advancer lifters 166 with a
small
angle to provide primarily lifting action to assist in breaking lump material
and
maintain a minimum dwell time within the breaker tube 100.
Material may be advanced out of D2 either as random tumbling of material
causes it to pass through to the advancing zone C3 advancers, or additional
infeed material is advanced through advancing zone C2 into lifting zone D2,
displacing the material already in zone 02. To reduce the amount of bitumen
inadvertently ejected from the discharge end 104, it is advantageous to reduce
the chances that random tumbling of material will cause advancement by
increasing the dwell time of lump material in lifting zones D2 and 03 closer
to the
discharge end 104. In this fashion material typically exits a zone due to the
advancement of additional material into the zone, displacing the material
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CA 02915349 2015-12-15
presently in the zone, or the material has been broken down sufficiently to
pass
through the perforations 121.
Advancing zone C3 contains advancer lifters 166 that advance the
material into lifting zone D3. Typically material will remain in lifting zone
D2 until
either random tumbling causes it to pass through to the advancing zone C3
advancer lifters 166, or additional infeed material is advanced through
advancing
zone 02 into lifting zone 02, displacing the material already in lifting zone
02.
Lifting zone 03 contains neutral lifters 168 that lift lump material with the
rotation of breaker tube 100 to drop the lump material onto the bottom portion
of
the breaker 110 to break the lump material into smaller pieces. The neutral
lifters
168 in lifting zone D3 may either be arranged in a similar pattern to lifting
zones
D1 and D2, or alternatively may be arranged in a different pattern to increase
the
dwell time of material advanced into the lifting zone 03.
Various embodiments of the present invention having been thus described
in detail by way of example, it will be apparent to those skilled in the art
that
variations and modifications may be made without departing from the invention.
The invention includes all such variations and modifications as fall within
the
scope of the appended claims.
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