Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02893161 2015-05-29
MINED ORE ANALYSIS AND CONTROL OF RELATED
MINING AND EXTRACTION PROCESSES
TECHNICAL FIELD
[0001] The following relates to the mining and extraction of hydrocarbons
from oil
sands and to methods of ore analysis and related control processes.
BACKGROUND
[0002] Alberta's oil sands are considered to be one of the world's largest
remaining
oil reserves. The McMurray Formation hosts the majority of the bitumen
resource in the
region, containing oil sands typically composed of about seventy to ninety
percent by
weight mineral solids (including sand and clay), about one to ten percent by
weight
water, with a bitumen or heavy oil content of up to twenty one percent by
weight.
[0003] In Alberta, only about twenty percent of the oil sands are
sufficiently shallow
to be recovered by surface mining, typically accomplished using large shovels
to
excavate ore from the mine face. The other 80% of oil sands reserves can be
recovered
using in situ recovery techniques, for example, Steam-Assisted Gravity
Drainage
(SAGD).
[0004] Due to the highly viscous nature of bitumen, recovering the
hydrocarbons
from mined oil sand ore generally requires various physical processing steps
in
combination with hot water and/or chemical treatment. In a typical hot water
extraction
process, hot process water is mixed with comminuted oil sands ore to form a
slurry, and
other agents such as flotation aids can be added. The slurry is agitated or
conditioned
for a period of time to form a bitumen-containing froth that can be separated
from higher
density tailings. The bitumen froth is processed and directed to downstream
upgrading
and refining operations.
Extraction of bitumen from mined oil sand ore is most efficiently accomplished
when
variations in ore quality and composition are minimal, allowing long term
process
optimization. When ore feeds varies, extraction processing irregularities can
result,
compromising product quality the economics of the extraction operation.
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CA 02893161 2015-05-29
SUMMARY
[0005] In a first aspect, there is provided a method for estimating the
composition of
surface-mined oil sands ore, the method comprising the steps of:
providing an ore analysis device comprising a near infrared light source, an
infrared light detector, and an infrared permeable window;
positioning the ore analysis device in a sampling location in proximity to a
path of
moving oil sands ore such that the infrared permeable window comes into direct
contact with mined oil sands ore;
operating the ore analysis device to emit and detect infrared light through
the
window to obtain a reflectance spectrum associated with an oil sands ore
sample in
direct contact with the window, wherein the window is positioned between (i)
the ore
sample and (ii) the infrared light source and light detector such that a fixed
distance
is maintained between the two during operation of the analysis device to emit
and
collect infrared signals; and
correlating the magnitude of the reflectance spectrum at one or more
wavenumbers of infrared light to a calibration curve to estimate at least one
composition parameter of the ore sample.
[0006] In an implementation, the magnitude of the reflectance spectrum is
correlated
at one or more wavenumbers of infrared light to estimate two or more
composition
parameters of the ore sample.
[0007] In some implementations, the composition parameter comprises:
bitumen
content, solids content, fine solids content, connate water content, chloride
content, solid
particle size distribution, methylene blue index, Ca+2 concentration, Na +
concentration,
K+ concentration, CO3-2 concentration, or SO4-2 concentration.
[0008] In some implementations, the composition parameter is bitumen
content and
the magnitude of the reflectance spectrum is correlated to a calibration curve
at one or
more wavenumbers between about: 9380 to 7417, 6102 to 5446 or 4790 to 4026 cm-
1.
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[0009] In some implementations the composition parameter is solids content
and the
magnitude of the reflectance spectrum is correlated to a calibration curve at
one or more
wavenumbers between about: 8092 to 7621 or 6456 to 5442 cm-1.
[0010] In some implementations the composition parameter is fine solids
content
and the magnitude of the reflectance spectrum is correlated to a calibration
curve at one
or more wavenumbers between about: 7891 to 6996 or 5550 to 5130 cm-1
[0011] In some implementations the composition parameter is connate water
content
and the magnitude of the reflectance spectrum is correlated to a calibration
curve at one
or more wavenumbers between about 7506 to 4713 cm-1.
[0012] In some implementations the composition parameter is chloride
content and
the magnitude of the reflectance spectrum is correlated to a calibration curve
at one or
more wavenumbers between about: 10348 to 7621, 5716 to 5342 or 4455 to 4026 cm-
1.
[0013] In some implementations the composition parameter is particle size
distribution and the magnitude of the reflectance spectrum is correlated to a
calibration
curve at one or more wavenumbers between about: 10348 to 7621, 5716 to 5342 or
4455 to 4026 cm-1.
[0014] In some implementations the composition parameter is Ca+2
concentration
and the magnitude of the reflectance spectrum is correlated to a calibration
curve at one
or more wavenumbers between about: 9403 to 6094 or 5454 to 4952 cm-1.
[0015] In some implementations the composition parameter is Na +
concentration
and the magnitude of the reflectance spectrum is correlated to a calibration
curve at one
or more wavenumbers between about: 9403 to 7498 or 5778 to -5446 cm-1.
[0016] In some implementations the composition parameter is K+
concentration and
the magnitude of the reflectance spectrum is correlated to a calibration curve
at one or
more wavenumbers between about: 7506 to 6094 or 5207 to 4952 cm-l.
[0017] In some implementations the composition parameter is CO3-2
concentration
and the magnitude of the reflectance spectrum is correlated to a calibration
curve at one
or more wavenumbers between about: 9403 to 6094 or 5454 to 4968 cm-1.
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[0018] In some implementations the composition parameter is SO4-2
concentration
and the magnitude of the reflectance spectrum is correlated to a calibration
curve at one
or more wavenumbers between about: 9403 to 7498 or 5454 to 4952 crn-1.
[0019] In some implementations the composition parameter is clay content
and the
magnitude of the reflectance spectrum is correlated to a calibration curve at
one or more
wavenumbers between about 9403 to 4944 cm-1.
[0020] In some implementations the composition parameter is methylene blue
index
and the magnitude of the reflectance spectrum is correlated to a calibration
curve at one
or more wavenumbers between about: 7506 to 6094 or 5454 to 4952 cm-1.
[0021] In some implementations the composition parameter is pH and the
magnitude
of the reflectance spectrum is correlated to a calibration curve at one or
more
wavenumbers between about 7506 to 4983 cm-1.
[0022] In an implementation, the method further comprises correlating a
plurality of
reflectance spectra corresponding to a plurality of ore samples to obtain
composition
parameter data for the plurality of ore samples; and based on the composition
parameter
data for the plurality of ore samples, determining an estimated quality of a
volume of
mined oil sand ore that includes the plurality of ore samples as a fraction of
the volume.
[0023] In an implementation, the infrared light detector captures infrared
light
reflected and scattered by the ore sample in response to the infrared incident
light.
[0024] In an implementation, the infrared light detected through the window
is
clarified, filtered or processed using a scattered light model to generate the
reflectance
spectrum for use in the correlating step.
[0025] In an implementation, the method further comprises processing the
composition data associated with the oil sands ore sample to detect if the oil
sands ore
was not in direct contact with the window when sampled.
[0026] In an implementation, the method further comprises correlating a
plurality of
reflectance spectra, corresponding to a plurality of ore samples, to a
calibration curve to
obtain composition data for each ore sample, and processing the composition
parameter
data for each ore sample in accordance with a model to select composition data
that
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meets criteria of the model, while excluding composition data that does not
meet criteria
of the model.
[0027] In an implementation, the method further comprises providing the
selected
data to a controller.
[0028] In an implementation, the ore analysis device is a near-infra red
(NIR) probe.
[0029] In some implementations, positioning the ore analysis device in a
sampling
location comprises positioning the device on or in proximity to equipment used
for mining
or processing of the oil sands ore such that direct contact between the NIR
probe and
the oil sands ore will occur.
[0030] In some implementations, equipment comprises: an apron feeder,
conveyor,
hopper, haul truck, excavation shovel or crusher.
[0031] In some implementations the ore analysis device is positioned such
that the
infrared permeable window is flush with an ore contacting surface of the
equipment.
[0032] In some implementations the ore analysis device is positioned such
that the
infrared permeable window is positioned in a path of moving oil sands ore.
[0033] In accordance with a further aspect, there is provided a surface
mining
method for extraction of bitumen from oil sands, the method comprising:
excavating a volume of oil sands ore and transporting the volume of excavated
ore to an ore processing facility;
prior to arrival of the volume of ore at the ore processing facility,
obtaining an
estimate of a composition parameter of the volume of ore by near-infrared
(NIR) spectral
analysis using an NIR analysis device comprising a near-infrared light source,
an
infrared detector and an infrared permeable window, wherein the window is
positioned in
direct contact with ore samples and between (i) the ore samples and (ii) the
infrared light
source and light detector such that a fixed distance is maintained between the
two
during operation of the analysis device to emit and collect infrared signals;
and
CA 02893161 2015-05-29
controlling a mining, ore processing or bitumen extraction operation based on
the
estimated composition parameter.
[0034] In an implementation, the ore processing facility comprises a slurry
preparing
facility.
[0035] In an implementation, the ore processing operation comprises a
slurry
preparation operation or an ore blending operation.
[0036] In an implementation, the composition parameter is bitumen content,
solids
content, fine solids content, connate water content, chloride content, solid
particle size
distribution, methylene blue index, pH, Ca+2 concentration, Na +
concentration, K+
concentration, CO3-2 concentration or SO4-2 concentration.
[0037] In an implementation, the NIR analysis device is an NIR probe
analyzer
installed in a sampling location on or in proximity of equipment in a system
for mining or
processing of oil sands ore.
[0038] In an implementation, the NIR probe analyzer is installed in
proximity to or in
contact with an apron feeder, conveyor, hopper, haul truck, excavation shovel,
or
crusher.
[0039] In an implementation, the probe is installed such that the window of
the NIR
probe is flush with an ore contacting surface.
[0040] In an implementation, the probe is installed such that an analysis
window of
the probe is placed into the path of moving ore.
[0041] In an implementation, the method further comprises processing the
estimated
composition parameters for each sample to derive an estimated quality of the
mined oil
sand ore.
[0042] In an implementation, the controlled operation is a mining operation
that is
controlled to change an excavation location based on the composition parameter
estimate.
[0043] In an implementation, the controlled operation is an ore blending
operation
that blends ore from two or more volumes of oil sands ore from different mine
faces.
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[0044] In an implementation, the controlled operation is an ore blending
operation
that blends ore from two or more volumes of oil sands ore excavated from one
or more
mines.
[0045] In an implementation, the method further comprises obtaining a
composition
parameter estimate of blended ore prior to arrival of the ore at a slurry
preparation
location, wherein the estimate is obtained by near infrared spectral analysis
using an
NIR analysis device in direct contact with the blended ore.
[0046] In an implementation, the controlled operation is a slurry
preparation
operation and wherein controlling the operation comprises controlling an
amount or
water, solvent, or other processing aid added to ore during slurry
preparation.
[0047] In an implementation, the controlled operation is a slurry
preparation
operation and wherein controlling the operation comprises controlling the
temperature of
water added to the ore when preparing a slurry.
[0048] In an implementation, the rate of slurry preparation is controlled.
[0049] In an implementation, a bitumen extraction operation is controlled.
[0050] In an implementation, a separation or flotation step in the
extraction operation
is controlled.
[0051] In an implementation, the residence time in a separation or
flotation vessel is
controlled.
[0052] In an implementation, the composition parameter estimate is used to
update
a mine map.
[0053] In accordance with a further aspect, there is provided a system for
estimating
composition parameters of ore moving through an ore processing operation, the
system
comprising:
one or more near infrared analysis devices, each infrared analysis device
comprising an infrared light source, an infrared light detector, and an
infrared
permeable window;
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each analysis device installed in a sampling location in proximity to a path
of
moving oil sands ore such that the infrared permeable window comes into direct
contact with mined oil sands ore moving through the ore processing operation;
the ore analysis device operable to emit and detect infrared light through the
window to obtain a reflectance spectrum associated with an oil sands ore
sample in
direct contact with the window, wherein the window is positioned between (i)
the ore
sample and (ii) the infrared light source and light detector such that a fixed
distance
is maintained between the two during operation of the analysis device to emit
and
collect infrared signals; and
a processor for processing the magnitude of the reflectance spectrum at one or
more wavenumbers in accordance with a model to estimate at least one
composition
parameter of the ore sample.
[0054] In an implementation, the system further comprises a controller
configured to
receive composition data from the processor and transmit signals to ore
processing
equipment in the ore processing operation in response to the estimated
composition
parameters.
[0055] In an implementation, the controller is further configured to
transmit signals to
an upstream mining operation.
[0056] In an implementation, the controller is further configured to
transmit signals to
a downstream extraction operation.
[0057] In an implementation, the ore processing operation is an oil sands
ore
processing operation for preparing ore to recover hydrocarbons from the ore.
[0058] In accordance with another aspect, there is provided a method for
estimating
the composition of oil sands ore samples, the method comprising the steps of:
emitting infrared light onto a plurality of oil sands ore samples in
succession,
where the distance between the emitted light and each oil sands sample is
consistent for
each oil sands sample;
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collecting infrared light reflected from each oil sands ore sample, where the
distance between the oil sands ore sample and a detector is consistent for
each oil
sands sample;
processing the reflected light collected by the detector to obtain a
reflectance
spectrum for each sample; and
correlating the reflectance spectra to a calibration curve to estimate at
least one
composition parameter of the oil sands ore samples.
[0059] In an implementation, the light is emitted and detected by a NIR
reflectance
probe in direct contact with each oil sands ore sample.
[0060] In an implementation, the oil sands ore sample is a core sample, is
obtained
from a core sample, or is a portion of a core sample.
[0061] In an implementation, the oil sands ore sample is ore moving through
a
mining or ore processing operation.
[0062] In an implementation, the estimated composition parameter is used to
create
or update a mine map or reservoir map.
[0063] In an implementation, the method further comprises detecting and
processing
infrared incident light scattered by the sample.
[0064] In some implementations, the sample is a mined ore sample.
[0065] In some implementations, the composition parameter comprises bitumen
content, solids content, fine solids content, connate water content, chloride
content,
solid particle size distribution, methylene blue index, pH, Ca+2
concentration, Na+
concentration, K+ concentration, CO2 concentration, or SO4-2 concentration.
[0066] In accordance with another aspect, there is provided a process for
obtaining
a blended mined oil sands ore feed comprising:
providing at least two feed streams of mined ore;
analyzing each feed stream using an infrared spectral analysis process in
which
an infrared analysis probe is placed in direct contact with mined ore samples
to estimate
two or more composition parameters of the mined ore;
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processing the composition parameter estimates to determine a blend ratio for
the feed streams, wherein the blend ratio results in a blended ore composition
that
meets a pre-determined specification; and
blending the mined ore from the feed streams in accordance with the blend
ratio.
[0067] In an implementation, the pre-determined specification is based on
feed
requirements for a downstream ore processing step.
[0068] In an implementation, the pre-determined specification is based on
fee
requirements of a downstream slurry preparation process or a downstream
bitumen
extraction process.
[0069] In an implementation, the bitumen extraction process is a hot water
extraction
process, solvent extraction process, flotation-based extraction process, or
mechanical
separation process.
[0070] In an implementation, an infrared analysis probe is installed in a
sampling
location in proximity to each feed stream such that ore moving within the feed
stream
comes into direct contact with the probe.
[0071] In an implementation, the probe is operated to emit and detect
infrared light
through a window to obtain a reflectance spectrum associated with an oil sands
ore
sample in direct contact with the window, wherein the window is positioned
between (i)
the ore sample and (ii) the infrared light source and light detector such that
a fixed
distance is maintained between the two during operation of the analysis device
to emit
and collect infrared signals.
[0072] In an implementation, the method further comprises a controller
configured to
receive composition estimates for each feed stream and control blending of the
mined
ore from the feed streams in accordance with the blend ratio.
[0073] In accordance with one aspect, there is provided a system
comprising:
a mining facility configured to excavate mined ore from a mine face;
a transportation system configured to transport the mined ore to an ore
processing facility;
an ore processing facility configured to receive and process the mined ore;
CA 02893161 2015-05-29
a plurality of near-infra red (NIR) analysis devices, each device comprising
an
NIR light source, an NIR light detector and an infrared permeable window
positioned
between the NIR light source and light detector, and an ore sample in direct
contact with
the window, wherein each device is positioned at a location in the system
where the
window comes into direct contact with the mined ore or a derivative thereof,
providing a
plurality of ore samples; and
a controller configured to:
receive signals from the plurality of NIR analysis devices;
correlate the signals to a calibration curve to estimate at
least one composition parameter of the plurality ore samples;
transmit signals to locations in the system to control one or
more operating parameters of the system in response to the estimated
composition
parameters.
[0074] In an implementation, the system further comprises an extraction
facility
configured to receive a slurry derived from the mined ore from the ore
processing facility
and to extract a resource from the slurry.
[0075] In an implementation, the controller is further configured to
control an
extraction process within the extraction facility based on the composition of
the mined
ore.
[0076] In an implementation, the extraction facility is a bitumen
extraction facility and
the extraction process comprises a flotation step.
[0077] In an implementation, the controller transmits signals to control
the addition of
hot water, chemicals, or other process aids at the flotation step.
[0078] In an implementation, the controller transmits signals to control
retention time,
flushing conditions, interface level, or withdrawal rates associated with the
flotation step.
[0079] In an implementation, at least one of the NIR analysis devices is
located in
the mining or transportation system; and composition parameters estimated for
ore
samples that were analyzed by said NIR analysis device are used by the
controller to
transmit signals to the mining facility, transportation facility, or
extraction facility to control
one or more operating parameters of the system.
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[0080] In an implementation, said NIR analysis device is located within an
excavator
used to mine ore, or within a haul truck used to haul the mined ore from the
mining
facility to the ore processing facility; and the operating parameter of the
system is an
excavation location.
[0081] In an implementation, said NIR analysis device is located within an
excavator
used to mine ore, or within a haul truck used to haul the mined ore from the
mining
facility to the ore processing facility; and the operating parameter of the
system is an
excavation rate.
[0082] In an implementation, said NIR analysis device is located within an
excavator
used to mine ore, or within a haul truck used to haul the mined ore from the
mining
facility to the ore processing facility; and the operating parameter of the
system is a
hopper or blend location for delivery of mined ore to the ore processing
facility.
[0083] In an implementation, at least one of the NIR analysis devices is
located in
the ore processing system; and composition parameters estimated for ore
samples that
were analyzed by said NIR analysis device are used by the controller to
transmit signals
to the mining facility, transportation facility, or extraction facility to
control one or more
operating parameters of the system.
[0084] In an implementation, said NIR analysis device is located in
proximity to a
hopper or conveyor used to transport mined ore; and the operating parameter of
the
system is a mined ore blending.
[0085] In an implementation, said NIR analysis device is located in
proximity to a
hopper or conveyor used to transport mined ore; and the operating parameter of
the
system relates to a processing step within the extraction facility.
[0086] In an implementation, the mining facility is an oil sands mining
facility for
recovery of hydrocarbons from the mined ore.
[0087] In an implementation, the controller is further configured to
compare the ore
composition to an expected ore composition prior to transmitting control
signals.
[0088] In an implementation, the controller is further configured to update
a mine
map or reservoir map based on the ore composition data.
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[0089] Implementations of the invention can realize some or none of the
following
advantages. The methods and systems described herein sample mined ore that is
in
direct contact with an infrared permeable window, behind which is an infrared
light
source and detector. The distance from the infrared light source and detector
to the
window is a constant, fixed distance. By only using samples that were taken
when the
mined ore is in direct contact with the window, the sample therefore is also a
fixed
distance from the infrared light source and detector when sampling occurs. The
magnitude of the distance is selected based on the desired composition data
for which
the sample is being collected. Advantageously, having the sample a fixed,
known and
pre-set distance from the infrared light source and detector during sampling
provides
improved reliability of composition analysis and data.
[0090] Being able to collect composition data for mined ore in near-real
time at one
or more locations in a mining and processing operation advantageously allows
the
operation to be controlled ¨ in near-real time ¨ to account for variations in
mined ore
feed to the processing operation. Processing and extraction operations
typically are
optimized for ore feed having composition parameters falling within a
particular range.
When ore feed enters the system outside these ranges, there can be adverse
consequences to the efficiency and economics of the processing and downstream
operations. Advantageously, these adverse consequences can be mitigated in at
least
two ways using the methods and systems described herein. Mining and
transportation
operations can be controlled based on the real-time composition data to
optimize ore
blending systems, to minimize variations in ore feed, thereby reducing
instances of the
problem. Additionally or alternatively, downstream operations (i.e., ore
processing
and/or extraction operations) can be controlled to account for the variations
in ore feed,
thereby mitigating the adverse consequences.
BRIEF DESCRIPTION OF THE DRAWINGS
[0091] Various aspects and implementations will now be described by way of
example only with reference to the appended drawings wherein:
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[0092] FIG. 1 is a process flow diagram of an example oil sands mining and
extraction system;
[0093] FIG. 2a and 2b show implementations of NIR probes for use in
estimating
ore composition;
[0094] Fig. 3 is a flow diagram of an implementation of an NIR reflectance
data
processing and control system
[0095] FIGs. 4a through 4m provide validation comparison scatter plots
comparing
an NIR predicted estimation to a laboratory measurement for multiple
composition
parameters;
[0096] FIG. 5 is a schematic representation of a surface mining and slurry
preparation system, in one embodiment;
[0097] FIG. 6 is a process flow diagram of an extraction system, in one
embodiment; and
[0098] FIG. 7 is a process flow diagram of an oil sands mining and
extraction
system, in one implementation.
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DETAILED DESCRIPTION
[0099] In a surface mining process and corresponding mined ore processing
system, the composition of mined ore can be determined by real-time analysis
of the
mined ore during transportation or processing. Analysis equipment can be
installed on
mining, transport, or processing equipment, and the resulting ore composition
data can
be used to both adjust upstream mining operations and optimize downstream
processes
for extraction of valuable resources from the mined ore.
[00100] Real-time NIR analysis of ore composition can be used to direct
ongoing
mining processes, and in blending mined ore feed streams to achieve a blended
ore
stream that meets operational specifications, e.g., for slurry preparation.
Further, the
analysis data can be used to advise downstream processing steps, for example
in
determining appropriate volumes and temperature of water and chemicals added
to the
ore to form a suitable slurry composition for efficient operation of a
downstream
extraction process, or to optimize specific processing steps in the extraction
of valuable
resources (e.g., hydrocarbons) from the ore, based on the analysis data.
[00101] In one implementation, ore analysis is accomplished by infrared
reflectance
analysis using NIR reflectance probes installed on ore transport or processing
equipment. When installed at one or more ore analysis locations, each NIR
probe makes
direct contact with mined ore moving past the analysis location, permitting
periodic or
continuous analysis of ore samples by the probe. The resulting NIR reflectance
spectra
are processed and correlated to a standard to determine the composition of
each ore
sample contacted and analyzed by the probe. This valuable composition data can
be
compared to expected or historical ore composition data. The analysis data is
further
useful in directing ongoing mining efforts or processing steps.
[00102] For illustrative purposes, the methods and systems are described
below in
the context of an oil sands mining operation for the purpose of extracting
bitumen from
the mined ore. However, it should be understood that the methods and systems
described herein can be used in other operations for mining ore and are not
limited to oil
sands mining.
CA 02893161 2015-05-29
Surface Mining Overview
[00103] Referring to Figure 1, a simplified process flow diagram
illustrating an
example oil sands surface mining operation is provided, although recovery of
other
resources from mined ore using the methods described herein is also
contemplated.
[00104] In the mining stage 100, oil sand ore is mined by excavation, which
can be
accomplished by suitable equipment as is known in the art, such as an electric
shovel or
excavator. Locations for excavation within the mine are typically determined
based on a
pre-determined mine map, generated using core sample laboratory analysis data
that is
extrapolated across the reservoir or geographical location to be mined.
Accordingly,
based on the mine map, the mine is generally represented by a grid in which
each cell is
assigned an estimated ore composition. For example, the estimated composition
for a
particular mine grid location may include estimated bitumen content, fines
content, 050
(representative of the grain size of sand, wherein a high 050 means the sand
is more
coarse), number of recoverable barrels of bitumen, ore grade, and other
parameters. As
the mine face is excavated and ore is loaded into haul trucks, an automated
system can
assign estimated composition data to each truckload of ore, based on the mine
map grid
location from which the ore was mined. For example, a GPS system associated
with the
shovel bucket can be used to estimate the composition of the truckload based
on the
various bucket positions while excavating ore from the mine face.
[00105] The mined oil sand ore is conveyed 102 to ore processing 104, for
example
by trucks and/or conveyors. The ore processing step 104 can include a crusher
or
comminutor to reduce the mined ore into a comminuted ore, and can further
include a
series of operations to blend and convert the mined oil sand ore into a
pumpable oil
sand slurry comprised of oil sand ore and process fluid. The pumpable oil sand
slurry
can be conveyed by hydrotransport 106 to an extraction facility 108.
Conveyance by
hydrotransport 106 may aid in conditioning the slurry, which improves
separation of the
bitumen in later processing steps. If conditioning is not required and the
extraction 108
facility is co-located with the ore processing 104 facility, hydrotransport
106 may not be
present. The process fluid can be a solvent such as water that has been heated
to a
process temperature, and optionally can include one or more additives such as
a diluent,
caustic, or other process aids. The slurry can be further diluted with process
fluids or
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additional additives at later stages in the operations, such as during
extraction 108,
where the pumpable oil sand slurry is processed and separated into a diluted
bitumen
product stream 110 and a tailings stream 111.
[00106] The diluted bitumen product stream 110 is transported to subsequent
downstream processing steps such as upgrading and refining 112, converting the
bitumen to various hydrocarbon products.
[00107] Tailings operations 114, serve to dispose of the tailings stream
111 that
results from the extraction process. For example, tailings can be deposited in
settling
ponds or can be subject to solid-liquid separation or other processing steps
leading to
disposal of solid waste and recycling of process water.
[00108] Ore processing 104 interfaces the inconsistent operation of mining
100 (due
to variations in volumes and composition of ore feed) and the continuous
operations of
extraction 108. Extraction processes operate most efficiently when ore feed
and process
steps can be consistently maintained within set operating parameters.
Ore Analysis
[00109] An ore analysis device can be installed in close proximity to, in
direct contact
with, or inserted into, oil sands ore during mining or ore processing, to
provide ore
composition data. Based on this composition data, mining operations and ore
processing
operations can be adjusted to minimize variations in slurry composition fed to
the
extraction process. Further, the data can be used to make adjustments to
optimize
downstream operations such as extraction, upgrading, and refining, based on
the
expected slurry composition. The ore composition data can also be used to
generate or
update a mine map or reservoir map.
[00110] The ore analysis device is provided for analyzing ore composition
at one or
more locations in the mining 100 or ore processing 104 operations, to obtain
estimated
composition data for various parameters of interest within the ore. Ore
composition
parameters for estimation in oil sands ore can include, for example, bitumen
content,
fines content, solids content, water (connate) content, concentration of
chlorides,
conductivity, D50 (a measure of particle size distribution), ore grade,
degradation state
of the bitumen, clay content, naphtha content, sulfate content, or bicarbonate
content. In
17
CA 02893161 2015-05-29
some implementations, the content of chlorides, potassium, calcium, sodium,
sulfates,
and/or carbonates, can be expressed as a concentration, e.g., in mg/L, and the
content
of bitumen, fines, minerals (solids), water, and clay can be expressed as a
percentage
by weight.
[00111] In some implementations, certain combinations of composition
parameters
can be estimated. For example, when the composition estimates will be used to
assign
an ore grade to the ore, the composition parameters estimated by NIR analysis
can
include bitumen, clay, and particle size distribution. Depending on the
purpose of the
data collection, various combinations of ore composition parameters can be
estimated.
The parameters can be used to advise downstream extraction operations, for
example to
estimate or model the recovery of bitumen using various extraction processes,
and to
predict recovery of bitumen, solids, and fines during each stage of extraction
108.
[00112] The ore analysis device can include one or more reflectance
infrared
spectrometers that direct infrared light toward an ore sample from a
controlled or fixed
distance, capture reflected light from a controlled or fixed distance, and
process the
captured light to obtain a reflectance spectrum. These functions can be
accomplished by
a single device, or each function can be carried out by independent devices
operating as
a system.
[00113] In some implementations, the ore analysis device includes a probe-
type
spectrometer that is placed in direct contact with the ore sample. The probe
can be, for
example, a reflectance near infrared probe spectrometer that can emit infrared
light and
capture infrared light that is reflected and/or scattered by the sample back
onto the
probe. An example of an NIR probe is shown in Figure 2a and 2b. In the
implementation
shown in Figure 2a, the probe 50 includes a steel flange portion 52 connected
to a steel
shaft portion 54. An infrared light-permeable window 55, such as a sapphire
window, is
located at a distal end 56 of the shaft portion 54. In Figure 2b, the shaft 64
of probe 60
extends through an equipment surface 61 and is held in place by anchoring
flange
portion 62 against the equipment surface. The infrared light-permeable window
65
makes direct contact with ore 90.
18
CA 02893161 2015-05-29
[00114] Placement of a probe in direct contact with the ore sample during
analysis
allows the distance for infrared reflectance analysis to be controlled and
consistent from
one sample to the next.
[00115] The beam of infrared light emitted onto the sample can include near
infrared
light, for example infrared light with a wavelength between about 800nm ¨
2500nm. In
some implementations, the ore analysis device is a Near Infrared Reflectance
spectroscopy (NIR) probe, or a collection of such probes, operable to direct a
beam of
infrared light through one or more infrared-permeable, impact resistant
windows (such
as a sapphire glass window) onto the ore. In embodiments in which the probe is
intended to directly contact, to abut, or to be inserted into a moving or
stationary source
of oil sands ore, the window provides a consistent analysis distance between
the light
source/detector and the ore sample, allowing controlled conditions for precise
and
reliable spectral analysis of samples moving past the window. Infrared light
reflected by
the ore is captured back through the window, and scattered light may also be
captured
through the window. Captured light (reflected or scattered or both) is
analyzed to obtain
a reflectance spectrum, which can be evaluated based on one or more models to
generate an estimate as to one or more composition parameters of the ore.
[00116] Each probe may include an analyzer for conversion of optical
signals,
corresponding to the collected infrared light reflected by an ore sample, to a
reflectance
spectrum. With reference to Figure 3, one or more probes 50, 60 can each be
operatively associated with an analyzer 70 that can receive optical signals
from each
probe corresponding to the infrared light reflected and/or scattered by
samples
contacting the window of the probe. The optical signals can be processed by
the
analyzer 70 to generate a reflectance spectrum, which is output as data
indicating the
magnitude of the infrared light reflected by the sample at various
wavenumbers. The
data can be sent to a processor 71 for correlation to a standard calibration
curve or
model, to provide ore composition data. The ore composition data can be
averaged over
a period of time to provide an estimated average ore composition. The ore
composition
information is transmitted to a controller 72 (either by wired or wireless
communication)
and can be used by the controller 72 to direct ongoing mining operations, ore
processing, and/or extraction operations. In some implementations, the probe
and
19
CA 02893161 2015-05-29
analyzer are integrated as one device. In some implementations, the processor
and
analyzer are integrated as one device. In some implementations, the processor
and
controller are integrated as one device. Other configurations are possible,
and the
configuration shown in Fig. 3 is but one example.
[00117] Each cycle of illumination and light capture can be referred to as
an analysis
interval. The analysis interval can be automated to take place at a desired
rate, for
example one analysis interval per second. During each analysis interval,
infrared light is
emitted through the window and light is captured through the window, whether
or not an
ore sample was in contact with the probe window during the analysis interval.
The
captured light from each analysis interval can be analyzed to generate a
reflectance
spectrum that is filtered or processed to determine whether the spectrum is
acceptable
for evaluation of ore composition. Alternatively, captured light from each
analysis interval
can be correlated to a calibration curve to determine the ore composition, and
the ore
composition data can be processed or filtered to determine whether the data is
acceptable.
[00118] The reflectance spectrum can be processed by applying chemometrics
to
evaluate the spectrum and to compare features of the spectrum to at least one
multivariate model. The model is calibrated off-line by collecting multiple
process stream
samples, and capturing spectra of each of the samples along with corresponding
reference laboratory results. Multivariate calibration techniques, such as
partial-least
squares regression (PLS regression), principal component analysis (PCA),
neural
networks (NNs), or other known means, can be used to construct a mathematical
model
that relates the spectrum to the content of a particular component of the
sample. The
spectrum can then be evaluated with reference to the model to obtain an
estimate of the
content of that component.
[00119] A separate model can be calibrated for each composition parameter
of
interest, and a set of models is used to evaluate more than one composition
parameter
of a bitumen-containing process stream. A separate set of models can be
calibrated for
each of different locations of interest.
[00120] Once a spectrum has been evaluated to generate an estimate of
various
composition parameters, the composition parameter estimates can be used to
inform
CA 02893161 2015-05-29
upstream or downstream operations. For example, further to receiving the ore
composition estimates, proactive or remedial actions can be taken to optimize
mining,
ore processing, blending, and extraction processes. The efficiency of
downstream froth
treatment, upgrading, and refining processes can also be improved as a result
of this
information.
Ore composition Parameters
[00121] Table 1 provides a list of ore composition parameters that can be
estimated
using near infrared spectral analysis, and corresponding filter windows
(wavenumber
ranges) for estimation of each parameter. As discussed above, the analysis can
be
completed using an NIR probe in direct contact with oil sands ore, which
contact
provides a consistent analysis distance between the sample light spot of the
probe.
TABLE 1: Wavenumber Ranges for Estimation of Ore Composition Laboratory
Parameters Using NIR Analysis
Parameter Wavenumber range (cm-1)
Bitumen 9380-7417, 6102-5446, 4790-4026
Solids 8092-7621, 6456-5442
Fines 7891-6996, 5550-5130
Connate water 7506-4713
Chlorides 10348-7621, 5716-5342, 4455-4026
Particle Size Distribution: for example, D45 6996-6102, 5550-4042, 6102-4520
Ca+2 9403-6094, 5454-4952
K+ 7506-6094, 5207-4952
Methylene Blue 7506-6094, 5454-4952
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CA 02893161 2015-05-29
Na + 9403-7498, 5778-5446
SO4-2 9403-7498, 5454-4952
pH 7506-4983
CO2 9403-6094, 5454-4968
Clay 9403-4944
[00122] The above wavenumber ranges are examples of wavenumbers that can be
used to process a reflectance spectrum and arrive at composition estimates.
That is, the
magnitude of the reflectance spectrum at one or more wavenumbers within the
above
ranges can be used for correlation to a standard curve/model for determination
of an
estimated content of the composition parameter within the ore. The magnitude
of the
reflectance spectrum at wavenumbers outside these ranges can also be
correlated to
composition parameters of interest.
[00123] With reference to Figures 4a through 4m, validation studies were
carried out
to compare ore composition results obtained using NIR analysis with
conventional
laboratory analysis.
[00124] Oil sand ore samples were obtained and analyzed in accordance with
standard laboratory practices. NIR analysis of the same samples was conducted
using a
Bruker Albedo probe. The probe was placed in direct contact with each ore
sample, and
a spectrum was collected across an 800-2500nm wavelength range.
[00125] With reference to Figure 4a, a validation model is shown, with the
sloped
line representing the ideal reference line between lab analysis and
corresponding NIR
analysis. As is observed from the model, in which the bitumen content of the
ore as
estimated by NIR analysis is indicated on the Y axis, and the corresponding
actual
bitumen content (as determined by laboratory analysis) indicated on the X
axis, there is
reasonable correspondence between the two methods of measurement, with an R2
of
98.06%.
22
CA 02893161 2015-05-29
[00126] Referring to Figure 4b, a validation model is shown, with the
sloped line
representing the ideal reference line between lab analysis and corresponding
NIR
analysis. As is observed from the model, in which the mineral (solid) content
(wt%) of the
ore as estimated by NIR analysis is indicated on the Y axis, and the
corresponding
actual mineral content (as determined by laboratory analysis) indicated on the
X axis,
there is reasonable correspondence between the two methods of measurement,
with an
R2 of 95.16.
[00127] Referring to Figure 4c, a validation model is shown, with the
sloped line
representing the ideal reference line between lab analysis and corresponding
NIR
analysis. As is observed from the model, in which the connate water content
(%) of the
ore as estimated by NIR analysis is indicated on the Y axis, and the
corresponding
actual connate water content (as determined by laboratory analysis) indicated
on the X
axis, there is reasonable correspondence between the two 'methods of
measurement,
with an R2 of 96.91.
[00128] Referring to Figure 4d, a validation model is shown, with the
sloped line
representing the ideal reference line between lab analysis and corresponding
NIR
analysis. As is observed from the model, in which the chloride content (mg/L)
of the ore
as estimated by NIR analysis is indicated on the Y axis, and the corresponding
actual
chloride content (as determined by laboratory analysis) indicated on the X
axis, there is
reasonable correspondence between the two methods of measurement, with an R2
of
96.71.
[00129] Referring to Figure 4e, a validation model is shown, with the
sloped line
representing the ideal reference line between lab analysis and corresponding
NIR
analysis. As is observed from the model, in which the Methlyene Blue index to
characterize clay content (m1/100g) of the ore as estimated by NIR analysis is
indicated
on the Y axis, and the corresponding actual Methylene Blue results (as
determined by
laboratory analysis) indicated on the X axis, there is reasonable
correspondence
between the two methods of measurement, with an R2 of 98.46.
[00130] Referring to Figure 4f, a validation model is shown, with the
sloped line
representing the ideal reference line between lab analysis and corresponding
NIR
analysis. As is observed from the model, in which the pH of the ore as
estimated by NIR
23
CA 02893161 2015-05-29
analysis is indicated on the Y axis, and the corresponding actual pH (as
determined by
laboratory analysis) indicated on the X axis, there is reasonable
correspondence
between the two methods of measurement, with an R2 of 94.24.
[00131] Referring to Figure 4g, a validation model is shown, with the
sloped line
representing the ideal reference line between lab analysis and corresponding
NIR
analysis. As is observed from the model, in which the Ca+2 content (mg/L) of
the ore as
estimated by NIR analysis is indicated on the Y axis, and the corresponding
actual Ca+2
content (as determined by laboratory analysis) indicated on the X axis, there
is
reasonable correspondence between the two methods of measurement, with an R2
of
97.96.
[00132] Referring to Figure 4h, a validation model is shown, with the
sloped line
representing the ideal reference line between lab analysis and corresponding
NIR
analysis. As is observed from the model, in which the CO3-2 content (mg/L) of
the ore as
estimated by NIR analysis is indicated on the Y axis, and the corresponding
actual CO3-2
content (as determined by laboratory analysis) indicated on the X axis, there
is
reasonable correspondence between the two methods of measurement, with an R2
of
96.29.
[00133] Referring to Figure 4i, a validation model is shown, with the
sloped line
representing the ideal reference line between lab analysis and corresponding
NIR
analysis. As is observed from the model, in which the K+ content (mg/L) of the
ore as
estimated by NIR analysis is indicated on the Y axis, and the corresponding
actual K+
content (as determined by laboratory analysis) indicated on the X axis, there
is
reasonable correspondence between the two methods of measurement, with an R2
of
98.29.
[00134] Referring to Figure 4j, a validation model is shown, with the
sloped line
representing the ideal reference line between lab analysis and corresponding
NIR
analysis. As is observed from the model, in which the Na + content (mg/L) of
the ore as
estimated by NIR analysis is indicated on the Y axis, and the corresponding
actual Na+
content (as determined by laboratory analysis) indicated on the X axis, there
is
reasonable correspondence between the two methods of measurement, with an R2
of
97.44.
24
CA 02893161 2015-05-29
[00135] Referring to Figure 4k, a validation model is shown, with the
sloped line
representing the ideal reference line between lab analysis and corresponding
NIR
analysis. As is observed from the model, in which the SO4-2 content (mg/L) of
the ore as
estimated by NIR analysis is indicated on the Y axis, and the corresponding
actual SO4-2
content (as determined by laboratory analysis) indicated on the X axis, there
is
reasonable correspondence between the two methods of measurement, with an R2
of
97.77.
[00136] Referring to Figure 41, a validation model is shown, with the
sloped line
representing the ideal reference line between lab analysis and corresponding
NIR
analysis. As is observed from the model, in which the Particle Size
Distribution <45pm
(%) of the ore as estimated by NIR analysis is indicated on the Y axis, and
the
corresponding PSD (as determined by laboratory analysis) indicated on the X
axis, there
is reasonable correspondence between the two methods of measurement, with an
R2 of
91.99.
[00137] Referring to Figure 4m, a validation model is shown, with the
sloped line
representing the ideal reference line between lab analysis and corresponding
NIR
analysis. As is observed from the model, in which the clay content (%) of the
ore as
estimated by NIR analysis is indicated on the Y axis, and the corresponding
actual clay
content (as determined by laboratory analysis) indicated on the X axis, there
is
reasonable correspondence between the two methods of measurement, with an R2
of
98.86.
Analysis Locations
[00138] In some implementations, an ore analysis device, such as a probe-
type
spectrometer, is installed on transport or processing equipment that is
continuously
exposed to moving bodies or samples of mined ore. For example, one or more
spectrometers can be installed within the wall of a conveyor, hopper or
crusher, to
rapidly and continually analyze ore moving past the analysis location during
ore
processing.
[00139] In some implementations, an ore analysis device can be installed on
transport or processing equipment that is periodically exposed to moving or
stationary
CA 02893161 2015-05-29
loads, bodies or samples of mined ore. For example, an ore analysis device can
be
placed in a haul truck or in contact with a surge pile to provide composition
analysis of
samples of mined ore.
[00140] Each spectrometer can be set to emit infrared light and obtain a
spectrum at
particular intervals to generate a representative sampling of the ore
composition being
mined and processed over time. The probe can be installed such that ore
continually or
periodically comes in direct contact with the ore as it advances through ore
processing.
[00141] In some implementations, ore analysis devices can be installed on
mining
equipment, for example, the probe can be fixed in place through a wall of an
excavation
bucket or haul truck bed. The probe can be located such that ore falls past
the probe
window during loading/unloading, allowing many sample analyses to be taken
during a
single loading or unloading event. As a bucket is dumped into the haul truck,
a steady
stream of mined ore can make contact with the probe as it passes. Depending on
the
location and number of probes installed, and the analysis rate and interval
that can be
achieved with each probe, many composition measurement intervals, or samples,
can
be analyzed during the unloading of a single bucket into the haul truck,
allowing multiple
measurements to be taken while loading a single truck with ore. The
measurements for
a single truckload can be averaged to estimate the ore composition of the
entire
truckload of ore.
[00142] Alternatively, or in addition to analysis during loading, one or
more probes
can be installed within the lower side walls or bottom surface of the haul
truck bed to
provide composition analysis of the stationary mined ore in the truck bed
during hauling.
Such probes can again be activated for analysis of ore during unloading of the
mined ore
from the truck bed, with continual rapid analysis during unloading as ore
moves past the
ore analysis location.
[00143] In some implementations, ore analysis devices can be installed on
various
types of equipment during ore processing. When installed within the wall of a
hopper,
crusher, or conveyor, an analysis device such as a NIR probe can be
continually
exposed to ore moving past the probe location. During some sampling intervals,
ore may
be in direct contact with the probe window, while in other intervals, ore may
not be in
direct contact with the window. Ore composition data can be filtered to
exclude data from
26
CA 02893161 2015-05-29
analysis, where the data is based only on an interval in which an ore sample
was not in
direct contact with the probe, to improve reliability of the ore composition
estimates.
[00144] A high sampling rate will generally allow increased reliability in
estimating
ore composition, particularly in sampling locations where a large proportion
of samples
are expected to be discarded due to lack of direct contact between the ore
sample and
the probe.
[00145] As the ore analysis device can be installed in a high impact
environment,
with many tonnes of material moving past the analysis location within minutes,
as
mentioned above, the online measurement apparatus can include a durable,
infrared-
permeable window, such as a sapphire optical window, positioned between the
infrared
incident light and the sample. Such window can form the end of a probe or be
used to
cover the end of a probe. The window can directly contact the sample, thereby
controlling the analysis distance of the sample from the incident light, and
also
controlling the distance of the sample from the reflected and scattered light
collector(s).
Such probes are readily available, for example the "Albedo" type probe from
Bruker Inc.
[00146] With reference to Figure 2b, in one implementation, the ore
analysis device
is an NIR probe-type analysis device. Such devices can include a fibre bundle
67
containing at least one NIR transmission fibre and at least one light
collection fibre. The
ends of these fibres are generally aligned so as to be the same distance from
the
sample. The end of the fibre bundle is termed a "light spot". When the fibre
bundle is
installed within an NIR analysis device for use in the analysis of oil sands
ore, the fibres
are positioned behind an infrared-permeable window 65 of appropriate thickness
and
durability to protect the fibres from contact with the ore, and to provide an
appropriate
and consistent analysis distance A between the light spot and the ore to be
analyzed.
[00147] In some implementations for use in analysis of mined oil sands ore,
the
infrared-permeable window can be flat or convex for easy installation and
alignment
within an equipment surface such as a hopper wall, to ensure that ore passing
the
analysis location will make contact with the window to permit analysis from a
controlled
distance. As mentioned, the window can be formed of infrared permeable, impact-
resistant glass, such as sapphire glass or sapphire crystal, for durability.
Repeated
27
CA 02893161 2015-05-29
contact of ore with the window serves the additional function of clearing
dust, bitumen,
clay, or debris from the impact-resistant window.
[00148] In some implementations, the ore analysis device is an NIR probe
having
one or more NIR transmission fibres, one or more light collection fibres, and
a window
between the fibres and the sample to be analyzed. Depending on the desired
installation
location, the ore analysis device can extend into the path of moving or
stationary ore
such that the probe is inserted into a volume of ore, with the window (flat,
curved, etc.)
providing a controlled analysis distance between the light spot and the
sample.
[00149] The light transmission and capture functions can be accomplished by
separate devices or probes, or separate fibre bundles, positioned behind a
common
window or behind separate protective windows. Each can be independently
programmed
to operate under specific conditions. For example, the incident light can be
provided
consistently at a particular rate, while the spectral analysis can be
processed at a
different rate based on independent criteria such as the degree of ore contact
or
proximity with the probe or window.
[00150] With reference to a light spot of an NIR analysis device, the most
reliable
and precise ore composition estimates will be obtained when the distance
between the
light spot and the ore sample is consistent for every sample. It should be
noted that the
distance of the light spot from the sample will, to some extent, determine
which ore
composition parameters can be reliably obtained. Certain parameters, such as
particle
size distribution, are more accurately estimated when the probe is in very
close proximity
to the sample, while estimation of other parameters do not require close
proximity to the
sample. Accordingly, the probe should be in direct contact with the ore
samples during
analysis, in order to maintain a consistent spacing of each ore sample from
the light
spot. The probe should be selected or designed with a window of an appropriate
spacing or thickness to provide a sample spacing from the light spot that will
provide
accurate and consistent estimation of all composition parameters that are
desired.
[00151] For any data point, light reflected by the sample and light
scattered by the
sample can be collected and processed. As distance from the sample increases,
the
reflected light alone may not provide a crisp spectrum for modelling of some
properties,
such as particle size distribution. For these parameters, the spectrum can be
clarified,
28
CA 02893161 2015-05-29
filtered, or further processed using a scattered light model. The need for
filtering or
processing can be determined based on the strength of the reflectance signal,
clarity of
the spectral shape compared to a standard, or other standard correlation
methods
known in the art.
[00152] Referring to Figures 2a and 2b, an NIR probe 50 is adapted for
insertion
through or within a wall opening 60 within a retention wall 61, for example a
retention
wall adjacent an apron feeder. As shown in Figure 2b, the probe can thereby be
secured
behind the wall 61 while extending through the wall to a position flush with
the wall or
extending into the ore conveying or processing area to contact ore 90.
[00153] In the implementation shown in Figure 2a, the probe 50 includes a
steel
flange portion 52 connected to a steel shaft portion 54. An infrared light-
permeable
window 55, such as a sapphire window, is located at a distal end 56 of the
shaft portion
54.
[00154] In some implementations, the probe embodiment can include a
lengthened
shaft portion for extending into the bitumen processing area and allowing more
direct
contact within the ore 90. In an implementation, the shaft portion 54 is has a
surface
metal coating to protect the portions of the probe exposed to the ore during
processing.
The coating provides increased strength to resist abrasion and corrosion, and
to assist in
preventing bitumen from adhering to the exposed portions of the probe. In some
implementations, the surface coating is a Nickel/Molybdenum based CK45 steel
metal
alloy.
Ore Processing
[00155] With reference to Figure 5, an example ore processing system 201
for use in
ore processing 104 is illustrated. As will be appreciated, the exact layout
and number of
conveyors and processing equipment can vary from site to site and the
embodiment of
Figure 5 is intended to provide an exemplary layout of equipment for
processing mined
oil sand ore for explanatory purposes. A truck 202 can be used to supply mined
oil
sands ore to a hopper 204, which receives and delivers loads of mined oil
sands ore to a
hopper apron feed conveyor 206. The ore is conveyed to a comminutor 208, e.g.,
a roll
crusher or other means known in the art. The hopper apron feed conveyor 206 is
29
CA 02893161 2015-05-29
typically a variable speed conveyor to allow control over the rate of
deposition of ore into
the comminutor 208.
[00156] The comminutor 208 crushes the received loads of ore into
comminuted ore
that is deposited onto a comminuted ore feed conveyor 210 and conveyed to an
optional
surge pile 212 that retains a store of ore. The comminuted ore feed conveyor
210 is
typically a constant velocity conveyor that provides a feed of comminuted ore
to the
surge pile 212.
[00157] The surge pile 212 stores the comminuted ore to allow for constant
delivery
of ore to a downstream slurry apparatus 218, as well as to provide buffer
capacity to
ensure a steady supply of ore during periods of upstream downtime (e.g. shift
change,
maintenance, etc.). The surge pile 212 can vary in volume and composition
according to
the supply of ore from the hopper apron feed conveyor 206 and comminutor 208.
[00158] The stored ore can be delivered from the surge pile 212 to a
reclaim apron
feed conveyor 214. The reclaim apron feed conveyor 214 is typically a variable
speed
conveyor that can convey the ore to a slurry apparatus feed conveyor 216. The
slurry
apparatus feed conveyor 216 is typically a constant velocity conveyor that
supplies ore
delivered from the reclaim apron feed conveyor 214 to a slurry apparatus 218,
such as a
rotary breaker. In the implementation shown, delivery of the stored ore from
the surge
pile 212 to the slurry apparatus 218 is effectively controlled by the variable
speed
reclaim apron feed conveyor 214.
[00159] Various ore analysis locations are possible within the ore
processing system
201. In some implementations, one or more ore analysis devices can be
installed at
hopper 204, adjacent apron feed conveyor 206 or comminuted ore feed conveyor
210, at
the feed or outlet end of the surge pile 212, and/or along reclaim surge apron
feed
conveyor 214.
Slurry Preparation
[00160] Referring to the implementation shown in Figure 5, a slurry
apparatus 218
receives ore from the slurry feed conveyor 216, and converts it into a slurry
with the
addition of process fluid 217. The slurry apparatus 218 provides a sizing
operation to
limit ore components of the slurry to a pre-determined maximum size. The
slurry
CA 02893161 2015-05-29
apparatus 218 provides the slurry to a slurry pump box 220 that feeds the
slurry to
hydrotransport pump 222. The slurry apparatus typically further includes
oversize
rejection 219 for diverting rejected rock and other mineral material that
cannot be sized
by the slurry apparatus 218. Oversize rejection 219 diverts the rejected
material,
typically to a reject pile, for temporary storage and then conveyance for
disposal as
backfill material. Hydrotransport pump 222 pumps the oil sand slurry through
hydrotransport 106 to extraction 108.
[00161] The ore processing system 201 can include other inputs such as
process
fluids 217 added to the slurry apparatus 218, process fluids 221 added to the
slurry
pump box 220, and process fluids 223 added at an outlet of the slurry pump box
220 to
control a composition of the oil sand slurry conveyed by hydrotransport 106.
Such
process fluids can include hot and/or cold process water, diluents, or other
conditioning
or flotation aids.
[00162] In various implementations, one or more ore analysis devices can be
installed along slurry feed conveyor 216, or at other locations within the
slurry
preparation portion of the ore processing system 201.
Ore Blending
[00163] Typical bitumen mining extraction operations are designed based on
an
expected ore grade, and the operational parameters are optimized as experience
is
gained in mining and processing the ore. It is expected that the ore grade,
quality, or
composition can vary to some degree between loads and gradually shifts over
time as
new areas of the mine are excavated. Significant variability in the ore
composition has
the potential to upset operational equilibrium and reduce performance,
resulting in
bitumen recovery losses, increased processing time, and reduced efficiency.
Notably, by
the time the out-of-specification ore composition would be flagged by a
standard
laboratory analysis or by visual observation of off-spec processing parameters
during
extraction, there may already be significant impact on economic returns of the
extraction
process. In addition, further processing steps may also be impacted in dealing
with this
off-spec feed to downstream operations.
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CA 02893161 2015-05-29
[00164] In order to control variability in ore composition and maintain
consistent feed
quality, ores from different sources or of differing grades can be blended
together to
achieve a desired feed grade or specification.
[00165] As described below, ore blending can be determined based on real-
time
estimated ore composition analysis. For example, ore composition may be
analyzed at
the stage of hauling the mined ore 102, or at the ore processing stage 104.
[00166] With reference to Figure 5, the ore processing system 201 can
include
multiple hoppers 204 for receiving mined oil sand ore from a multiple trucks
202 at
different locations at the mine site. Truckloads of mined ore are thereby
combined at
each hopper 204 and become blended during ore processing to form a blended
supply
of ore at each surge pile 212.
[00167] The composition of mined oil sand ore delivered to each of the
hoppers 204
can be monitored in real-time using NIR analysis to estimate the blended ore
composition downstream of the hoppers 204. Further, when ore analysis devices
are
installed at the excavators and/or on the haul trucks, the blend of ore at
each hopper can
be controlled by directing each truck to a particular hopper based on the
estimated ore
composition of the mined oil sands ore in the truck.. By subsequent analysis
of ore
composition at an ore processing location downstream of the hopper 204 (such
as at
conveyor 210 or 214, or at the surge pile 212) the desired ore blend can be
verified prior
to the ore reaching the slurry apparatus 218.
[00168] The use of multiple hoppers 204 in parallel may be a preferred
arrangement
to accommodate blending of ore from various sources or of varying quality, and
blending
at each hopper may be controlled to achieve a different blended ore
composition
downstream of each hopper, if desired. By operating multiple hoppers 204 in
parallel,
estimates of the ore quality or composition at each hopper may be monitored
and
controlled independently. Installation of an ore analysis device at the point
of excavation,
at each hopper 204, and at other locations within the ore processing system
201 can
provide real-time monitoring of ore composition parameters to optimize
blending at the
parallel hopper locations.
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CA 02893161 2015-05-29
[00169] Conventionally, if ore blending is implemented, it is based on
estimated
bitumen content, which is determined from the mine map. However, since the
mine map
is itself estimated and subject to a standard of error, and the excavation
process is also
imprecise, the estimates upon which the ore blending are typically based do
not allow
sufficient optimization of bitumen recovery. Real-time analysis of mined ore
and/or
blended ore can provide current actionable information about the ore as it is
fed into the
ore processing system 201. Providing reliable composition information allows
adjustments to be made to the ore processing and bitumen extraction processes,
to
optimize the efficiency and economics of bitumen recovery. For example,
extraction
processes can be optimized to use less process water, reduced volumes of
chemical
process aids, and reduced energy inputs while allowing higher throughput,
reduced
maintenance and improved product quality.
Extraction
[00170] Referring to Figure 6, a simplified diagram of an extraction system
300 is
provided. The simplified system shown excludes many additional operations that
can be
involved in extraction, and focuses on high level systems that produce a
product stream
of interest. As will be appreciated, a working facility can include multiple
copies of
elements contained in the Figure, as well as additional recycling and
processing systems
not shown. In Figure 6, an oil sand slurry is received for primary extraction
by a Primary
Separation Vessel (PSV) 306 from hydrotransport line 106. The PSV 306 operates
to
separate the oil sand slurry into three layers: a bitumen froth layer that
includes bitumen
froth and some process fluid that floats to the top of the cell 306; a
middlings layer that
includes some froth, a mineral component and process fluid; and, a lower
tailings layer
that predominantly includes a heavier mineral component and some process
fluid.
[00171] The bitumen froth layer is separated from the top of the PSV 306 as
a
bitumen froth stream 315 for further extraction processing. The middlings
layer is
typically separated through middlings output stream 309 for processing, such
as in
flotation tank 308, to separate a bitumen rich middlings component from a
tailings
component. As illustrated, the flotation tank 308 separates the bitumen rich
middlings
component, which can be returned to the PSV 306 for further processing through
middlings return stream 310, and the tailings component is output through
middlings
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CA 02893161 2015-05-29
tailings stream 312 for processing or disposal as tailings 114. A tailings
stream 311 is
extracted from the tailings layer of the PSV 306.
[00172] Samples are typically taken at various locations during the
extraction
process, which are subject to laboratory analysis. The laboratory analysis can
be used to
adjust operation of the PSV 306. However, a limitation of this adjustment
method is the
delay between mining the ore, collecting the samples during extraction,
obtaining a
laboratory analysis and, in response, adjusting operating parameters. A
typical
laboratory analysis can take 24 hours to obtain ¨ by which time the sample
upon which
the analysis was based has long since passed through the extraction system
300, and
later-mined ore, potentially having quite a different composition, may be
currently
processing. Accordingly, conventional operations tend to default to using
excess process
inputs such as water, diluent, and other process aids to ensure bitumen
recovery stays
above a minimum acceptable threshold, since reliable ore blends and/or
composition
estimates have not been available.
[00173] When ore analysis devices are used to monitor mined ore composition
at
one or more ore analysis locations throughout the ore processing system 201,
the slurry
feed 106 to the extraction process can be controlled and off-spec parameters
can be
managed by modification of extraction process operating parameters. For
example, the
clay content of ore included in the slurry feed can be used to determine an
appropriate
amount of process water to add to the PSV 206; the bitumen content or ore
quality of the
slurry feed can be used to adjust the PSV residence time; and the fines
content and
degree of ore degradation can be used to determine whether additional
reagents, e.g.,
caustic, should be added. The bitumen residence time in the PSV can be
adjusted by
raising or lowering the froth/middlings interface height in the PSV to provide
increased or
decreased residence time. This can be accomplished, for example, by adjusting
the
underflow withdrawal rate. Generally, the froth interface level in the PSV can
be raised
when bitumen content or ore quality is high, reducing the residence time; or
lowered
when excessive fines are expected to require more time to achieve separation.
[00174] Operation of the extraction process in response to ore analysis can
also be
effected by adjusting the process fluids added at various locations or stages
of
extraction. Hot process water can be added as froth underwash within the upper
portion
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CA 02893161 2015-05-29
of the PSV below the interface when increased fines concentration in the ore
feed is
detected. A conical flush of the lower portion of the PSV with hot or cold
water can be
implemented in combination with reduced intake of slurry into the PSV 206, to
increase
the bitumen recovery rate when the ore feed is of lower quality.
[00175] Referring again to Fig. 5, hot process water and additives can be
added to
the hydrotransport line or at the rotary breaker during slurry preparation
when poor
quality ore is detected. The temperature of the process water can also be
adjusted in
response.
[00176] When the ore quality is recognized as being out of specification,
adjustments
can be made in extraction and/or by adjusting the ore blend from various
locations,
and/or adjusting shovel locations. However, to date, adjustments in blend or
in mining
location have only been possible based on the mine map, which is subject to a
degree of
error as discussed previously. Ore composition analysis during mining and/or
ore
processing provides increased reliability in quickly identifying the need to
adjust mining
locations or ore blend. Updates can be made to the mine map based on the real-
time
analysis of the mined ore.
[00177] Accordingly, ore quality or processing conditions can be determined
based
on real time ore composition analysis.
Core Analysis and Reservoir Mapping
[00178] The analysis of ore by NIR can also be useful in generation of a
mine map
or reservoir map. Prior to recovery of bitumen or other resources from a
geographic
location, core samples are obtained and subjected to laboratory-based
composition
analysis. The number and location of core samples are typically selected to
allow
geologists to gain insight into the geological structures and resource
content. While a
larger number of core samples is desirable, the time and cost of analyzing
core samples
ultimately limits the number of core samples that can be taken, and geologists
must
generate a reservoir map based on limited core sample data, in combination
with data
that may be available from other sources or observations. Inherently, mine
maps
generated using these conventional techniques have inaccuracies.
CA 02893161 2015-05-29
[00179] NIR-based composition analysis of core samples can be used to
reduce the
cost of core sample analysis by avoiding costly laboratory services, and
further allows a
greater number of samples to be analyzed without increasing costs. The
analysis of a
large number of samples, or analysis of additional core samples in areas of
the reservoir
where there is some uncertainty in structure or composition, improves
reliability of the
reservoir map. Analysis of the core samples can be completed on site when a
core
sample is obtained: portions of the core sample of particular interest can be
collected
and analyzed using a portable NIR analyzer in real time. This real-time
analysis of core
samples on site can inform selection of the next core sample location, and
whether a
suitable number of samples have been collected for a particular geographic
region. It is
also contemplated that data from real-time NIR composition analysis can be
collected by
a controller and processed in accordance with pre-determined schemes or
operational
algorithms to automate certain aspects of the system. The controller can also
collect
additional data from complementary systems for integration across the mining
and ore
processing functions. For example, in a mining operation that includes mine
face
analysis, the mine face analysis data may be correlated with the NIR ¨based
composition estimates of the mined ore from that mine face, to provide more
robust data
regarding ore analysis and ore composition within the mine. Such integration
can, over
time, reduce reliance on prior core sample data (which may be inaccurate), in
favor of
actual data obtained during mining operations. An updated mine map can then be
generated for the excavated portion of the mine and extrapolated to the
unexcavated
areas of the mine, which can advise further mining efforts in the region.
System Control Based on Composition Parameter Estimates
[00180] In an implementation, mined ore composition estimates can be
processed in
real-time, or near real-time, allowing for efficient remedial or preventative
action to be
taken in an upstream or downstream location to mitigate impact of varying ore
feed
parameters. Online NIR slurry analysis within the extraction system can be
used to
evaluate the effectiveness of process changes made on the basis of ore
composition
analysis.
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CA 02893161 2015-05-29
Bitumen Content / Ore Grade
[00181] In some implementations, the bitumen content and/or ore grade of
mined
ore being transported during mining or ore processing is estimated by NIR
analysis. The
estimated bitumen content can be used to determine whether remedial or
preventative
action should be taken at upstream or downstream operational steps. For
example,
when the bitumen content of a mined ore stream ¨ as estimated by NIR at a
particular
hopper or conveyor - is below a lower threshold level, blending of the ore
stream can be
adjusted. For example, the low bitumen ore stream can be blended at a lower
rate with
another ore stream that meets the threshold, or the low bitumen ore stream can
be
blended at the same rate or even a higher rate with an ore stream that is
higher in
bitumen content, or that is even above an upper threshold bitumen content.
Excavation
from amine face with undesirable ore quality can be quickly recognized and
halted,
avoiding further costs of unwanted mining activity. Truckloads of low quality
ore that has
already been excavated can be discarded or reassigned to non-extraction
purposes.
[00182] Other adjustments that can be made based on a low bitumen content
might
include increasing the amount of process water or caustic during slurry
preparation.
When the estimated bitumen content of a mined ore stream is below the
threshold for a
prolonged period, the mined ore can be segregated and used as fill, and the
excavation
site can be reviewed while directing excavation efforts to other areas of the
mine.
[00183] When bitumen content is above an upper threshold, this may cause
the ore
to become difficult to handle and process, especially during warm ambient
temperatures.
Accordingly, ore blending can be adjusted, conveyor speed can be adjusted to
speed
transport of the ore, and extraction can be optimized to reduce the amount of
water and
process aids added. The estimated bitumen content data can further be used to
update
the mine map accordingly.
Fines Content / Clay content
[00184] In an implementation, the fines and/or clay content of the ore
being
transported or processed is estimated by NIR analysis, and the estimated fines
content
can be used to proactively adjust downstream extraction steps. For example,
when the
fines content of a mined ore stream ¨ as estimated by NIR at a particular
hopper or
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CA 02893161 2015-05-29
conveyor - is below a lower threshold level, blending of the ore stream can be
adjusted
(manually or automatically) to bring the fines content of the blended ore
stream into a
desired range. In another example, high fines content may warrant withdrawal
of
middlings from the primary separation cell at an increased rate, and/or
increased
addition of water during flotation-based separation to allow the bitumen to
separate from
the fines and float to the surface of the cell. The estimated fines content
can be used to
control the middlings withdrawal and/or rate of water addition accordingly.
Other Parameters
[00185] In various implementations, one or more of many typical oil sands
composition parameters are estimated by NIR analysis, and can be used to
determine
whether remedial or preventative action should be taken at upstream or
downstream
steps in the extraction system. For example, estimation of the particle size
distribution
can allow the hydrotransport process to be efficiently managed to avoid
sanding out of
the hydrotransport line. Examples of measurements conventionally determined by
laboratory analysis that can be estimated using the ore analysis methods
described
above include: bitumen content, fines content (e.g. particle size <45 pm),
mineral (solids)
content, water content, clay content, chloride content, sulfate content,
potassium
content, calcium content, sodium content, carbonate content, particle size
distribution,
pH value, and methylene blue index. Other measurements can also be estimated.
With
reference to Figure 7, ore composition estimates obtained during the course of
mining,
transport, processing, and extraction operations can be used by a controller
710 to
modify ongoing system operations. During mining efforts within mining facility
702, ore
composition can be estimated using conventional methods, such as consulting a
mine
map based on core sample data. In addition, real-time analysis of ore
composition can
be completed as discussed above. For example, ore analysis devices can be
installed in
excavators to analyze samples of ore as it is mined, with the resulting
composition
estimates provided to the controller 710, which can be a centralized system
for collection
of mining data and control of mining equipment. Ore analysis devices can be
installed on
haul trucks of the transportation system 704, providing ore composition data
for loads of
or ore 712 transported by haul trucks. The ore composition data is provided to
the
controller, which can control mining and transportation efforts based on ore
composition
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CA 02893161 2015-05-29
and truck availability. For example, based on the ore composition data
received at the
controller 710, the controller 710 can control truck movement to optimize
efficiency of the
transportation operation and/or to optimize ore blending at hoppers included
in the ore
processing facility 706. Trucks can be directed by the controller 710 to an
appropriate
hopper within the ore processing facility 706 to achieve a desired ore blend
within each
hopper stream of the ore processing facility. Ore analysis devices can be
installed within
the ore processing facility 706, such as adjacent conveyors, to verify the
composition of
the ore present within the ore processing facility. Installation of one or
more ore analysis
devices just prior to the slurry preparation step within the ore processing
facility can
provide verification of the ore blend used to prepare an oil sand slurry,
thereby providing
reliable ore composition to the extraction facility 708.
[00186] Should the
ore composition estimates at any location indicate that the ore at
a particular stage is not of appropriate composition, the controller 712 can
adjust any
steps within the mining, transportation, ore processing, or extraction
operations
accordingly.
[00187] The examples and corresponding diagrams used herein are for
illustrative
purposes only. The principles discussed herein with reference to oil sands
mining can
be implemented in other mining systems, and for analysis of other types of
mined ore.
Different configurations and terminology can be used without departing from
the
principles expressed herein. For instance, steps, equipment, components, and
modules
can be added, deleted, modified, or re-arranged without departing from these
principles.
[00188] Although the above principles have been described with reference to
certain
specific examples, various modifications thereof will be apparent to those
skilled in the
art, as outlined in the appended claims.
39
