Method and apparatus to create an oil sand slurry

Abstract

An improved method and apparatus for preparing and oil sand slurry. Mined oil sand ore is deposited into a rotatable breaker tube. As the rotary breaker rotates, the ore is advanced and broken. Process fluid may be differentially distributed throughout the length of the rotary breaker, forming an oil sand slurry and assisting in the comminution and ablation of the ore. The comminuted oil sand and process fluid passes through perforations in the interior surface of the rotary breaker, and are collected in a hopper below, while oversized ore lumps are ejected out of the discharge end of the rotary breaker. The rotatable breaker tube is resistant to backflow at higher infeed rates.

1 . An apparatus 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.   
   
   
       2 . The apparatus of  claim 1  wherein the process fluid source supplies process fluid at differential rates at different locations within the tube. 
   
   
       3 . The apparatus of  claim 2  wherein the process fluid source supplies a greater quantity of process fluid near the infeed end than the quantity of process fluid supplied near the discharge end. 
   
   
       4 . The apparatus of  claim 3  wherein the process fluid source supplies at least 60% of the process fluid at a front half of the rotatable tube. 
   
   
       5 . The apparatus of  claim 2  wherein the process fluid source supplies a greatest quantity of process fluid at an oil sand deposition site near the infeed end and a least quantity of process fluid at a discharge section near the discharge end. 
   
   
       6 . The apparatus of  claim 2  wherein the process fluid source further comprises an infeed set of nozzles to direct the greater quantity of process fluid near the feed end and at least a second set of nozzles to direct the quantity of process fluid supplied near the discharge end. 
   
   
       7 . The apparatus of  claim 6  wherein the infeed set of nozzles has more nozzles per unit area than the at least a second set of nozzles. 
   
   
       8 . The apparatus of  claim 1  wherein the process fluid source comprises a sparge pipe extending through the tube. 
   
   
       9 . The apparatus of  claim 8  wherein the sparge pipe is positioned at a top portion of the breaker tube. 
   
   
       10 . The apparatus of  claim 9  wherein the sparge pipe is positioned off-centre in the direction of intended rotation of the tube. 
   
   
       11 . The apparatus of  claim 8  wherein the sparge pipe further comprises nozzles to supply process fluid. 
   
   
       12 . The apparatus of  claim 11  wherein the quantity of nozzles per unit area is different at different locations along the sparge pipe. 
   
   
       13 . The apparatus of  claim 12  wherein the quantity of nozzles per unit area is greater at an infeed section of the sparge pipe than at a discharge section of the sparge pipe. 
   
   
       14 . The apparatus of  claim 12  wherein the sparge pipe consists of an infeed section and a discharge section and the quantity of nozzles per unit area is greatest in the infeed section and least in a discharge portion of the discharge section. 
   
   
       15 . The apparatus of  claim 11  wherein the size of the nozzles differs at different locations along the sparge pipe. 
   
   
       16 . The apparatus of  claim 15  wherein large nozzles are located at an infeed section of the sparge pipe and small nozzles are located at a discharge section of the sparge pipe. 
   
   
       17 . The apparatus of  claim 15  wherein the sparge pipe consists of an infeed section, and a discharge section and the largest nozzles are located in the infeed section and the smallest nozzles are located at a discharge portion of the discharge section. 
   
   
       18 . The apparatus of  claim 11  wherein alternate nozzles are offset to provide varied delivery of process fluid. 
   
   
       19 . The apparatus of  claim 11  wherein alternate nozzles are aimed with offset trajectories to provide varied delivery of process fluid. 
   
   
       20 . The apparatus of  claim 11  wherein end nozzles direct process fluid towards a central portion of the breaker tube. 
   
   
       21 . The apparatus of  claim 11  wherein the nozzles are recessed within the sparge pipe. 
   
   
       22 . The apparatus of  claim 8  further comprising a baffle plate for dividing the sparge pipe into two sections, an infeed sparge pipe section and a discharge sparge pipe section, the infeed sparge pipe section exiting from and supplied with process fluid from the infeed end of the tube, and the discharge sparge pipe section exiting from and supplied with process fluid from the discharge end of the tube. 
   
   
       23 . The apparatus of  claim 22  wherein an infeed flow rate of process fluid is supplied to the infeed sparge pipe section at a different flowrate than a discharge flow rate supplied to the discharge sparge pipe section. 
   
   
       24 . The apparatus of  claim 23  wherein the infeed flowrate is greater than the discharge flowrate. 
   
   
       25 . The apparatus of  claim 24  wherein the infeed sparge pipe section is the same length as the discharge sparge pipe section. 
   
   
       26 . The apparatus of  claim 22  wherein the infeed sparge pipe section is of a longer length than the discharge sparge pipe section. 
   
   
       27 . The apparatus of  claim 22  wherein the infeed sparge pipe section is of a shorter length than the discharge sparge pipe section. 
   
   
       28 . The apparatus of  claim 26  wherein an infeed flow rate of process fluid is supplied to the infeed sparge pipe section at the same flowrate as a discharge flow rate supplied to the discharge sparge pipe section. 
   
   
       29 . The apparatus of  claim 8  wherein the sparge pipe is enclosed within a protective shell pipe. 
   
   
       30 . The apparatus of  claim 29  wherein the protective shell provides structural support for the sparge pipe. 
   
   
       31 . The apparatus of  claim 1  wherein the process fluid source comprises 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. 
   
   
       32 . The apparatus of  claim 1  wherein the process fluid source comprises:
 an infeed supply pipe positioned at the infeed end of the breaker tube; and,   nozzles on the infeed supply pipe arranged to direct process fluid into the breaker tube at a portion of the interior surface.   
   
   
       33 . The apparatus of  claim 32  wherein the infeed supply pipe comprises an inverted U-shape. 
   
   
       34 . The apparatus of  claim 32  wherein at least some of the nozzles comprise jet nozzles to direct a jet spray of process fluid into the breaker tube. 
   
   
       35 . The apparatus of  claim 1  further comprising:
 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.   
   
   
       36 . The apparatus of  claim 35  wherein the discharge supply pipe comprises an inverted U-shape. 
   
   
       37 . The apparatus of  claim 36  wherein at least some of the nozzles comprise jet nozzles to direct a jet spray of process fluid into the breaker tube. 
   
   
       38 . The apparatus of any one of  claims 1  wherein the process fluid comprises water. 
   
   
       39 . The apparatus of  claim 38  wherein the water is heated. 
   
   
       40 . The apparatus of  claim 38  wherein the process fluid further comprises a process aid. 
   
   
       41 . 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, at least a section of the tube perforated;   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 adapted to advance the received ore as the tube rotates away from the infeed end;   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 adapted to lift and drop lump ore; and,   a discharge end of the tube for receiving oversized material from the breaking zone as reject material and discharging reject material.   
   
   
       42 . The apparatus of  claim 41  wherein the lifting elements comprise neutral lifters for lifting ore. 
   
   
       43 . The apparatus of  claim 42  wherein the neutral lifters present a contact face at about 0° to the longitudinal axis of the breaker tube. 
   
   
       44 . The apparatus of  claim 41  wherein the lifting elements comprise advancer lifters for lifting and advancing oil sand ore toward the discharge end. 
   
   
       45 . The apparatus of  claim 44  wherein the advancer lifters present a contact face at about 5°-25° to the longitudinal axis. 
   
   
       46 . The apparatus of  claim 41  wherein the lifting elements comprise a combination of neutral lifters and advancer lifters. 
   
   
       47 . The apparatus of  claim 41  wherein the breaking zone comprises a set of advancer lifters for lifting and advancing ore to a set of neutral lifters. 
   
   
       48 . The apparatus of  claim 47  wherein the breaking zone further comprises multiple sets of neutral lifters, each set of neutral lifters delineated by a set of advancer lifters. 
   
   
       49 . The apparatus of  claim 47  wherein the set of advancer lifters comprise a ring of advancer lifters radially distributed about the interior surface of the tube. 
   
   
       50 . The apparatus of  claim 47  wherein the set of neutral lifters comprise at least two adjacent rings of neutral lifters radially distributed about the interior surface of the tube. 
   
   
       51 . The apparatus of  claim 50  wherein the neutral lifters are arranged such that neutral lifters in adjacent rings are offset. 
   
   
       52 . The apparatus of  claim 41  wherein the breaking zone comprises lifting elements arranged to present a contact face at an angle parallel to the longitudinal axis of the breaker tube. 
   
   
       53 . The apparatus of  claim 52  wherein the breaking zone further comprises advancing elements arranged to present a contact face at an angle to the longitudinal axis of the breaker tube for lifting and advancing ore toward the discharge end. 
   
   
       54 . The apparatus of  claim 52  wherein the breaking zone comprises at least two groups of lifting elements, each of the groups of lifting elements delineated by a set of advancing elements. 
   
   
       55 . The apparatus of  claim 52  wherein the lifting elements are arranged in a staggered formation across the interior surface. 
   
   
       56 . The apparatus of  claim 52  wherein the number of lifting elements per unit area is constant within the breaking section. 
   
   
       57 . The apparatus of  claim 52  wherein the number of lifting elements per unit area decrease within the breaking section toward the discharge end. 
   
   
       58 . The apparatus of  claim 41  wherein the advancing elements comprise paddles for advancing ore. 
   
   
       59 . The apparatus of  claim 41  wherein the advancing elements comprise ploughs for advancing ore. 
   
   
       60 . The apparatus of  claim 41  wherein the advancing elements are arranged to present a contact face at an angle to the longitudinal axis of the breaker tube. 
   
   
       61 . The apparatus of  claim 60  wherein the advancing elements present the contact face at about 30°-45° to the longitudinal axis. 
   
   
       62 . The apparatus of  claim 60  wherein adjacent advancing elements are arranged in-line along the contact faces. 
   
   
       63 . The apparatus of  claim 62  wherein the adjacent advancing elements are arranged in close proximity to provide a line of contact faces extending into the breaker tube. 
   
   
       64 . A method of 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;   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 in 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;   passing a further sized fraction and a remainder of the process fluid through perforations in 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 action and the remainder of the process fluid to produce the oil sand slurry.   
   
   
       65 . The method of  claim 64  wherein advancing elements projecting from the interior surface act upon the advanced deposited ore to separate the sized fraction from the lump fraction. 
   
   
       66 . The method of  claim 64  wherein lifting elements projecting from the interior surface act upon the advanced lump fraction to lift and drop the advanced lump fraction. 
   
   
       67 . The method of  claim 66  wherein advancing lifting elements act to lift and advance the advanced lump fraction to neutral lifting elements that act to lift and drop the advanced lump fraction. 
   
   
       68 . The method of  claim 64  wherein advancing elements projecting from the interior surface act upon the advanced deposited ore to separate the sized fraction from the lump fraction and, lifting elements projecting from the interior surface act upon the advanced lump fraction to lift and drop the advanced lump fraction. 
   
   
       69 . The method of  claim 64  wherein lifting elements projecting from the interior surface act upon the advanced lump fraction to lift and drop the advanced lump fraction. 
   
   
       70 . A method of 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 the breaker tube into a separation zone;   directing a supply of the process fluid towards an interior surface;   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 in the breaker tube;   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, a further sized fraction of the ore and a remainder of the process fluid passing through further perforations in 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 action and the remainder of the process fluid to produce the oil sand slurry.   
   
   
       71 . A method of 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 the breaker tube;   directing a supply of the process fluid towards an interior surface of the breaker tube;   breaking a lump fraction of the ore by lifting and dropping the lump fraction creating further sized material;   passing the perforation sized material, the further perforation sized material and the process fluid through perforations in the breaker tube; and,   collecting the passed material and the process fluid to produce the oil sand slurry.   
   
   
       72 . The method of  claim 71  further comprising, before breaking the lump fraction, separating the lump fraction from the perforation sized fraction by passing the perforation sized material through the perforations and advancing the lump fraction. 
   
   
       73 . The method of  claim 71  further comprising directing a first quantity of process fluid to assist in the separation and a second quantity of process fluid to assist in the breaking. 
   
   
       74 . The method of  claim 73  further comprising directing a first quantity of process fluid to assist in the separation and a second quantity of process fluid to assist in the breaking. 
   
   
       75 . The method of  claim 74  wherein the second quantity of process fluid further comprises a breaking quantity of process fluid and a discharge quantity of process fluid. 
   
   
       76 . The method of  claim 75  wherein the breaking quantity comprises a larger flowrate than the discharge quantity. 
   
   
       77 . The method of  claim 74  wherein the first quantity comprises a larger flowrate than the second quantity. 
   
   
       78 . The method of  claim 71  wherein at least a portion of the supply of process fluid comprises directing process fluid down a top surface of a slope sheet to deposit at the deposition site. 
   
   
       79 . The method of  claim 78  further comprising spraying process fluid at the top surface of the slope sheet. 
   
   
       80 . The method of  claim 71  wherein at least a portion of the supply of process fluid comprises spraying process fluid at the deposition site. 
   
   
       81 . The method of  claim 71  wherein at least a portion of the supply of process fluid comprises spraying process fluid into the breaker tube from the infeed end. 
   
   
       82 . The method of  claim 71  wherein at least a portion of the supply of process fluid comprises spraying process fluid into the breaker tube from the discharge end. 
   
   
       83 . The method of  claim 71  wherein at least a portion of the supply of process fluid comprises spraying process fluid at a portion of the interior surface where the lump fraction is dropped. 
   
   
       84 . A method of 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;   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 material, the further perforation sized material and the process fluid to produce the oil sand slurry.   
   
   
       85 . The method of  claim 84  further comprising adjusting the delivery of the ore based on the measurement of the quantity of ore. 
   
   
       86 . The method of  claim 85  wherein the delivery is adjusted to increase the delivery when the measurement indicates a low level of ore. 
   
   
       87 . The method of  claim 85  wherein the delivery is adjusted to decrease the delivery when the measurement indicates a high level of ore. 
   
   
       88 . The method of  claim 85  wherein the measurement comprises measuring a weight of ore being carried by the conveyor. 
   
   
       89 . The method of  claim 85  wherein the measurement comprises measuring a height of ore being carried by the conveyor. 
   
   
       90 . The method of  claim 89  wherein the height is measured by a level meter. 
   
   
       91 . The method of  claim 85  wherein the measurement comprises measuring a weight and a height of ore being carried by the conveyor. 
   
   
       92 . The method of  claim 91  wherein the delivery is adjusted when there is a discrepancy between the weight and the height of ore being carried by the conveyor. 
   
   
       93 . The method of  claim 92  wherein the adjustment comprises decreasing a delivery of ore when the discrepancy indicates a larger quantity ore being carried by the conveyor. 
   
   
       94 . The method of  claim 92  wherein the adjustment comprises increasing a delivery of ore when the discrepancy indicates a smaller quantity ore being carried by the conveyor. 
   
   
       95 . The method of  claim 92  wherein the adjustment comprises increasing a supply of process fluid when the discrepancy indicates a larger quantity ore being carried by the conveyor. 
   
   
       96 . The method of  claim 92  wherein the adjustment comprises decreasing a supply of process fluid when the discrepancy indicates a smaller quantity ore being carried by the conveyor.