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Boswell J., Alostaz M. & Pinheiro M. (2012) Insights into oil sands tailings development projects. In: Intl.

Oil
Sands Tailings Conference, IOSTC, Edmonton, AB, 2-5 December, 2012, pp. 73-81.

INSIGHTS INTO OIL SANDS TAILINGS DEVELOPMENT PROJECTS


Jeremy Boswell, M.Eng., Michael Alostaz, Ph.D., P.Eng. and Mauricio Pinheiro, Ph.D.,
Thurber Engineering Ltd.

ABSTRACT The business, public and regulatory environment is


constantly changing for Oil Sands tailings.
The nature of the Oil Sands industry places Objectives which were entirely valid and appeared
somewhat unique demands on the design, most reasonable to even the most experienced
engineering and management of tailings eye at the outset of the project, seem to become
development projects, designs and field trials. dated and flawed in quite short time frames - in a
matter of months rather than years.
Among the many challenges faced by tailings
development projects are: scale of operations and Faced with these and many other constraints to
scale-up; public, environmental and regulatory delivery over the past five years, the authors have
requirements; cross-functional demands and co- developed a number of techniques and key
ordination; seasonality, schedule and timelines; learnings which hold promise in enabling the timely
managing continuous project changes and change completion of tailings development projects within
of scope, schedule and priority level. budget.

Faced with increasing demands to deliver tailings THE TOP NINE CHALLENGES
solutions, the implementation of tailings technology
development projects has become more and more 1. Clear, Consistent Objectives
challenging, as a myriad of competing demands
require answers simultaneously, against a Perhaps we could introduce this section by reading
backdrop of multiple variables. from Alice in Wonderland:
In this paper the authors describe some of the The Cat only grinned when it saw Alice. It looked
unique challenges to project managers in tailings good- natured, she thought: still it had VERY long
development, and offer some tools, insights and claws and a great many teeth, so she felt that it
approaches into successfully addressing these ought to be treated with respect.
demands, including: the development of project
objectives, potential remedies in considerations of `Cheshire Puss,' she began, rather timidly, as she
scale-up; proactive anticipation and nimble did not at all know whether it would like the name:
response to client requirements; understanding, however, it only grinned a little wider. `Come, it's
experience, track record and continuity; pleased so far,' thought Alice, and she went on.
mobilization and efficient use of multidisciplinary `Would you tell me, please, which way I ought to
resources; decision-making, risk assessment and go from here?'
technical review; cost tracking; timely and effective
communication; careful record-keeping and `That depends a good deal on where you want to
document tracking; sustained team motivation and get to,' said the Cat.
attention to detail. `I don't much care where--' said Alice.
`Then it doesn't matter which way you go,' said the
INTRODUCTION Cat.
`--so long as I get SOMEWHERE,' Alice added as
Tailings technology development projects in the Oil an explanation.
Sands over the past two decades have met with `Oh, you're sure to do that,' said the Cat, `if you
considerable difficulties in achieving the objectives only walk long enough.'
which were originally set. Why is this so? What are
the pitfalls facing Oil Sands tailings technology Perhaps Lewis Carroll knew a thing or two about
development, and how could they be better the Oil Sands.
handled?
Some tailings development projects fail simply
because their purpose or objectives were never
defined, understood and agreed between the key Laminar sheet flow of slurry is always
players at the outset. The risk of this all-too- associated with deposition.
common occurrence can be greater if the project: Laminar flow cannot persist over long
has multiple sponsors, distances since zone settling within the
is of long duration (or conversely is being flowing layer will lead to deposition after a
done in a rush), finite period of time.
is highly technical, Turbulence can overcome zone settling.
is controversial or sensitive, Thus for long distance travel the tailings
attempts to modify objectives on the fly, forms itself into a concentrated turbulent
or channel.
attaches success to the development of It is postulated that the slope of the
the technology, rather than to the quality channel will be steep enough for the
of the research. generated turbulence to just overcome
zone settling.
Clearly the key is to define the purpose of the The overall beach slope of the stack is
project, set objectives and sub-objectives. therefore determined by the limiting
Prioritized objectives may be useful if trade-offs equilibrium channel slope which is
are later required in order to make progress. required for a particular tailings, to create
the required steady state turbulent total
2. Scale up transport flow condition in the self-formed
channels.
Based on full-scale, flow-through flume
One of the most daunting challenges encountered testing, the following observations have
in the development of Oil Sands tailings been made:
technology, is that of scale up. Many simply avoid o The average velocity, the Froude
the issue and the technology development often No., the velocity profile with depth,
fails, as a result. and the density profile within the
flow are essentially constant for a
Complexity
given slurry and do not vary with
flow rate.
It is not simply because Oil Sands projects are o The critical channel slope for full
very large (copper and other tailings facilities are of transport of the tailings, and
an equivalent size). Oil Sands tailings projects possibly the critical Reynolds
have become very complex in recent years, number, vary with flow rate.
requiring specialist inputs in fields as diverse as
polymer chemistry, computational fluid dynamics, Beach profile
unsaturated soil mechanics, rheology, two-phase
flow, environmental science and patent law. Morris and Williams (1996) state:
The relationships between the profiles of full-size
Literature scan
and laboratory-model deltas are analysed using
the principles of kinematic similarity and a recent
In a brief review of published papers, and in theory of delta formation based on engineering
discussion with two tailings experts, the authors hydraulics. Measured profiles of full-size and
found that little exists in literature as a guide. model coal-mine tailings deltas are compared and
Those limited references which were found, are the prediction of full-size profiles is discussed. It is
listed and described in brief, below: shown that the data derived from laboratory-model
deltas are insufficient to enable accurate prediction
Laminar and turbulent slurry flow regimes of full-size delta profiles. Initial slope data or other,
equivalent data for the full-size delta are also
Pirouz et al (2005) describe thickened tailings as a required.
viscous fluid with non-Newtonian behaviour in
which scale effects can be significant and are a Open channel flow hydraulics
serious issue in the study of the phenomenon.
They conclude for tailings beach flow and Researchers in water engineering have long
deposition: employed models to investigate fluvial, estuarine
and marine flow behaviour to predict
sedimentation, scour and other phenomena, and shown to be effective at the small scale. Tests at a
as tools in hydraulic engineering design. larger scale are required to examine its
applicability to the field. Many of the assumptions
Two dimensionless parameters often used in open of lubrication theory may not hold: certainly, at
channel formulas, including those applied in the some mines the velocity of the tailings as they exit
prediction of tailings beach profiles, are the Froude the pipe may be quite fast and the flow may be
number: turbulent, though the authors believe the flow
(Fr = v g h) becomes laminar at some distance from the pipe,
and therefore the geometry will be largely
and Reynolds number: controlled by laminar flow. Another assumption
(Re = v h ) that may not hold true is the time independence of
numbers, where v is the mean flow velocity, h is rheological properties - it is possible that some
the depth of flow, is the kinematic viscosity, and tailings may undergo significant settling and
g is the gravitational acceleration. dewatering as they flow. This fact may turn out to
be advantageous to mine operators, as it may be
Flume tests, lubrication theory, surface tension possible to rely on settling enhanced by
and momentum desiccation through evaporation and the wicking
action of the underlying layer, to increase the yield
Of the references cited in this memo, the work of stress to that required for deposition. Though
Fourie and Gawu (2010) and Morris and coworkers possible, this kind of deposition would be complex
best accounts for scalability issues in flume tests. to control.

Fourie (2012) adds: At the flume scale we have Pumping and pipeline systems
not resolved the potential interference of factors
such as surface tension or interference and Cooke (2012) indicates: there are challenges with
merging flow from multiple flumes or channels. scaling up pump and pipeline transport systems,
but I am not aware of any papers that have dealt
In fluid dynamics, lubrication theory describes the with this issue. It has been on my mind to write a
flow of fluids (liquids or gases) in a geometry in paper on the limitations of slurry pipeline transport
which one dimension is significantly smaller than but I have not yet managed to find the time.
the others. Surface tension may then be
significant, or even dominant. Issues of wetting Scale up challenges in Oil Sands technology
and dewetting then arise. (Wikipedia, 2012) development
Fourie adds further: Likewise, I am unaware of In describing the potential for Retort-Based
any papers dealing specifically with this issue. The Extraction (a possible non-water based extraction
issue of beach slope development must be method in which heat is used to vaporize any
affected by scale up, especially when considering water and generate pyrolysis of the bitumen, the
the massively larger volumes (and therefore waste coke can be used as a fuel source for future
momentum) involved. extraction and the remaining tailings are free of
bitumen and other hydrocarbons) as an alternative
Simms et al (2009) record: tailings technology, the AIberta Innovates Oil
Sands Tailings Roadmap report (2012) laments
The flume test visualization studies showed that that:
lubrication theory based equations described the
measured flows quite well. This theory may Scale-up. This technology is still in the
partially explain the discrepancy between overall development phase. To date, the largest pilot can
deposition angles reported in the field and those in only process 1/30th of the amount of ore that is
the laboratory, as it clearly shows that this angle is normally produced in one train using current
scale dependant. Testing at larger scales and with extraction techniques.
more complex flow geometries is still required to
characterize the usefulness of this approach to And in reference to chemical alternative tailings
planning field deposition. treatments:
The use of lubrication theory based equations to
model the evolving geometry of paste tailings was
In pursuing the development of chemical 5. Product has space and time varying
amendments to Oil Sands tailings, the following properties
challenges should be considered: 6. Product to model scaling is not uniform or
constant
High cost to evaluate chemical 7. Product behavior has no or complex
amendments at pilot scale. governing equation
Uncertainty surrounding technical aspects 8. Product has no realizable simple model;
of the chemical amendments and a lack of 9. Parameters have no realizable experiment
understanding of how they work. 10. Experimentation has unrealistic time scale
Performance can be highly variable due to
changes in input chemistry which could Computational Fluid Dynamics (CFD)
render results very lease specific.
Scale up - Quantity and cost of chemical One of newer and more promising fields of tailings
required for commercial scale operations research is that of Computational Fluid Dynamics,
can be considerable. or CFD. Even in this field and perhaps starkly so,
the issue of scale-up is critical. Strategic
The report does offer some solutions: dependence on the use of Camp number (itself
dependent on pipe dimensions) is reflective of this
Develop a series of standard trials and evaluation realization.
tools to evaluate the potential of chemical
amendments at first the lab scale then the pilot Potential Remedies for the Challenge of Scale
scale. The evaluation criteria should be both short Up
and long term focused.
How should these many challenges of scale up be
Empirical Similitude Method in other addressed? (Most practitioners appear to be
engineering applications agreed that this is becoming a critical issue).
However, the solution is not simple and answers
In a recent Ph.D. thesis, Tadepalli (2009) are not readily to hand. The authors suggest the
describes the difficulties encountered in many new following approach(es) as a starting point:
fields of engineering with modeling, scale-up, or
similitude. In describing the development of an 1. Review published literature for evidence of
Empirical Similitude Method (ESM), Tadepalli scale dependence for the parameter(s)
records: under consideration.
Analyzing the behavior of a system with a network 2. Recognize which parameters are scale
of components requires multifaceted dependent, and which ones are not (for
approximations to reasonably simplify the example, flume test width, momentum and
modeling effort. More often than not, a dominant surface tension effects appear to be key in
phenomenon is isolated that captures a major considerations of scale).
segment of the system response without 3. Isolate the key parameters which are most
compromising the integrity of the governing dependent on scale, researching their
dynamics of the associated physical process. Such influence on project parameters one at a
a simplification cannot be achieved with time.
considerable ease and requires numerous 4. Attempt to describe in fundamental
approximations and assumptions. scientific terms or at the very least in
empirical terms, the nature of the influence
Although describing the difficulties of modeling of each key scale dependent parameter.
engineering components in a typical manufacturing 5. Establish the minimum scale of pilot test
setting, Tadepalli goes on to list a number of required to provide meaningful results, by
factors which would give rise to the need to use a a combination of research, fundamental
more abstract model to model non-linear behaviour analysis, modeling and lab scale testing.
(in a variety of scientific research fields), including: 6. Explore the potential for increased
1. Product/Model has distortions understanding and characterization, by
2. Product has material non-linear responses successive modeling at gradually
3. Product has multiple materials increasing scales, while tracking the
4. Product has variable inputs and, initial and change between stages from:
boundary conditions a. Lab (characterization) testing.
b. Lab (batch and comparative) substantial. This has placed a premium on
testing. executives to be familiar with tailings matters and
c. Individual pilot testing. to be well advised by specialist tailings engineers
d. Batches of pilot tests (in sequence at first hand.
or in parallel).
e. Prototype testing. Tailings projects also demand the focused
7. Calculate, consider and compare the attention and commitment of senior engineering
relative costs, risks and benefits of field leadership from the consultant, with rigorous
testing at increasingly large scales, in scrutiny at the Oil Sands Geotechnical Review
order to establish the most promising scale Board level.
of test, for the parameters under
investigation. Close teamwork and a relationship of trust
between client and consultant are fundamental.
In implementing the steps above, the following This comes into sharp focus while pro-actively
aspects should also be borne in mind: responding to and managing the inevitable
changes which occur in projects of this nature,
Step 3 (above) may imply an uncoupled approach. sometimes arising out of a change in the big
In reality, many parameters are not completely picture. This is amplified in section 5 below.
independent of one another and isolation of
parameters from one another may be difficult. It
may then be useful to reconsider the choice of
4. Continuity, Skills and Teamwork
parameters by selecting only those which are truly
independent from one another. In addition, some Working in a young and evolving industry such as
parameter selection occurs as early as Step 1, and the Oil Sands is both exciting and challenging at
may be influenced by the choice of approach or the same time. It offers tremendous opportunities
test method. for learning; however it has its own unique ongoing
challenges that require input from experienced
The modelling of open channel flow has suggested specialists with a thorough working knowledge of
that in situations where multiple scale dependant Oil Sands tailings and geotechnical engineering
variables are present, there is no simple alternative and who know what will work and what will not,
but to resort to larger prototypical models. without wasting time and resources on repeat work
and trials.
The project manager should resist the temptation
to over-accelerate development, thereby missing The challenge in the Oil Sands is the limited
development steps (by leaving out essential steps number of those specialists who are available to
in the sequence such as researching the promptly respond to the demands of daily mining
fundamentals, lab testing, pilot testing, etc.) or by operations. Also, it is commonplace to change the
attempting to perform steps in parallel, rather than responsibilities and roles of those specialists to
sequentially. accommodate the needs of different areas of
operation. These challenges can be overwhelming,
Technical subject matter experts should remain allowing no time for creative thinking and
involved in all successive development stages, in innovative solutions to be developed, and which
order to ensure that scale up effects are fully disrupt communications and project continuity.
considered and addressed during the project.
These challenges can be lessened through the
The use of an analogue fluid or material may be efficient use of available resources, by assembling
considered, (such as is already used in the teams of professionals with the necessary skill sets
modelling of fluid flow and mixing in pipelines, and to assist in responding to the tailings project
in association with CFD and elsewhere). demands, and who can call in specialist expertise
when needed in a timely and effective manner.
The specialist needs to provide strategic guidance
to team members, to brief them in detail, to
3. Skilled Leadership measure their progress and to work closely with
them to ensure timely completion of agreed
Responsibility for tailings related decision-making deliverables within budget.
is now vested at most senior levels, as the
implications for Oil Sands operators are
This will provide the Oil Sand industry with much of simply reacting on the spur of the moment to
needed and well-trained teams of dedicated challenges as they arise.
professionals who have in-depth experience of
tailings projects, who promote continuity between To promote healthy growth in Oil Sands tailings
projects and who maintain effective two-way management, it is insufficient to keep using the
communication within each project team, as well same techniques and practices without recognizing
as with outside specialists. special opportunities when they come along. It is
important to then make conscious decisions based
5. Big Picture Thinking on a sound understanding of the engineering
principles of tailings to create opportunities, and in
The unique challenges posed in Oil Sands tailings so doing encourage step-change advances in the
in recent times have demanded with increasing industry.
clamour the need for big picture thinking. The
turning point was perhaps the publication by the Pro-active research requires a clear understanding
ERCB on February 3, 2009 of Directive 074, and of the industry operational, financial and regulatory
more recent promising initiatives by industry and drivers. It should ask the questions: Where is the
government to develop common objectives for the industry going? Where should it go next? How will
management and reclamation of Oil Sands tailings. it get there? Who will take it there, and in what
steps? The research clearly requires input and
There is continued need to consider big picture feedback from the operators, regulators and
aspects during tailings engineering and industry experts.
development projects, on account of ongoing
media, public and regulatory scrutiny and interest. Creativity and the ability to generate alternative
This was addressed in a paper two years ago at responses to future challenges that will face
this forum, Boswell (2010): industry are key elements of pro-active research.
These elements require the input of independent
This paper suggests the view that the Big Picture forward-thinking individuals who can mentally
is managing the interface between: generate and evaluate different options, and have
the freedom to explore unique solutions without
being restricted or forced to conform to corporate
Tailings
boundaries or prevailing social norms and public
The Environment
expectations. Academic and industry research
The Public bodies need to be engaged in the process to
examine and verify the scientific principles of the
Big Picture Thinking encompasses five
proposed solutions.
components:

Technical 7. Scientific Critique and Rigorous


Operational Review
Environmental
Legal A fundamental attribute of high quality research is
Public the capacity to invite and address the scrutiny of
scientific critique and peer review. This applies in
This subject is expanded upon in the paper the Oil Sands no less.
referenced above, as well as in the references
cited in the paper at the time. At the same time however, the hard-nosed Oil
Sands tailings technology development champion
6. Pro-active Independent Research is aware that in order for continued progress to be
made, a little deafness to critics may be required
There is an abundance of learning opportunities for project success.
which are yet to be captured, in order to enhance
the practice of Oil Sands tailings management. The challenge is to be able to strike a balance and
Adopting a pro-active research philosophy will in so doing to:
allow the Oil Sands industry to shape its own Differentiate valuable technical critique
future and engineer its own opportunities, instead from unfounded criticism.
Identify fatal flaws in technology addressing difficulties with intellectual
development at the earliest possible property.
juncture, and to address them as a Make use of sufficiently knowledgeable
priority. specialists who are able to draw from wide
Establish a project reputation which experience.
maintains a readiness to receive critique. Build understanding and knowledge of the
particular demands of Oil Sands
A number of project structures and mechanisms technology development, when drafting
may be useful in allowing a project to receive contracts; recognize the need for skills in
critique and thereby improve engineering contract negotiation; bridge the gap
robustness and the chances of success: between engineers, attorneys and
accountants, in setting up project
Risk awareness, and a constant vigilance structures and communication lines.
for potential fatal flaws. Recognize the circumstances under which
Anticipation and planning in advance for protection of intellectual property is
contingencies and risks. required and those instances where it is
Regular use of risk assessment not; avoid unnecessarily draconian
techniques, such as a Probable Failure clauses (for example, indefinite protection
Modes Analysis (PFMA), Value of rights in perpetuity).
Engineering, Quality Circles or SHERQ Maximize the opportunities to improve co-
there are many examples; a project operation within the Oil Sands industry
structure and schedule which allows for presented by the formation of the Oil
these inputs in a timely manner. Sands Tailings Consortium (OSTC), and
All work produced by the team to be more recently Canadas Oil Sands
subject to a rigorous internal review, Innovation Alliance (COSIA). COSIA is an
before being released. alliance of Oil Sands producers focused on
A close working understanding between accelerating the pace of improvement in
consulting Team and Senior environmental performance in Canada's
Geotechnical Reviewers, and knowledge Oil Sands through collaborative action and
of the requirements and function of the innovation.
Review team. Proactive measures to encourage and
A publish-or-perish commitment to involve vendors and suppliers especially
sharing of research findings in journals of those from outside of the Oil Sands.
high standing, specifically inviting
comment and critique. 9. Planning, Control and Discipline

8. Intellectual Property and There are a number of conventional project


Contracts management skills and disciplines, which when
systematically applied, are capable of delivering
Recent technology development in the Oil Sands even difficult projects on time and within budget.
has struggled at times in dealing with the demands They include:
of intellectual property rights, and delays
occasioned by the requirements of contract 1. Technical accuracy. Attention to detail and
negotiations. technical accuracy in analysis and design;
use of skilled engineers experienced in
There are remedies however: state-of-the-art analysis techniques and
software.
2. Control. Disciplined project management
Allow sufficient lead time at the outset of
and control of resources, schedule and
the project for the development,
negotiation and agreement of contracts budget in a spirit of no surprises.
dealing with necessary clauses for 3. Documentation: Careful record keeping
and documentation of the design process
intellectual property, patents, copyright,
and results as they become available; a
non-disclosure and contractual remedies.
philosophy of recording key events and
Be flexible (regarding information transfer,
decisions.
deliverables, schedule, resourcing) in
4. Reporting. An ongoing discipline of 7. Calculate, consider and compare the
summarizing and updating key relative costs, risks and benefits of field testing at
geotechnical information, results and increasingly large scales, in order to establish the
recommendations into a comprehensive most promising scale of test, for the parameters
set of Design Memos, long before the under investigation.
Final Report deadline.
5. Communication and record-keeping. ACKNOWLEDGEMENTS
Keeping the whole team aware of
progress, and the changing needs of the The inputs and advice of our colleagues in Thurber
project; tracking the status of documents, (Dr. John Sobkowicz, Chris Workman, Trempess
ensuring that the most current information Moore, Iain Gidley and Morgan Kofoed) and
is continuously available. elsewhere (Prof. Andy Fourie from the University
of Western Australia and Dr. Robert Cooke of
CONCLUSIONS Paterson & Cooke, Denver, USA) is gratefully
acknowledged.
The authors have presented nine challenges
encountered in the project management of Oil REFERENCES
Sands tailings technology development projects.
For each challenge they offer a few insights and AIberta Innovates Oil Sands Tailings Roadmap
solutions towards addressing these challenges: Report (2012). Alberta Innovates Energy and
Environment Solutions OIL SANDS TAILINGS
1. Clear, consistent objectives. TECHNOLOGY DEPLOYMENT ROADMAP
2. Scale up. Project Report Volume 5 Component 4 Results
3. Skilled leadership. http://ai-ees.ca/media/7369/1906-
4. Continuity, skills and teamwork. component_4_report.pdf
5. Big Picture Thinking.
6. Pro-active, independent research. Boswell, J.E.S. (2010). Big Picture Thinking in Oil
nd
7. Scientific critique and rigorous review. Sands Tailings. In: 2 OSTRF Conference.
8. Intellectual property and contracts. Edmonton, Canada.
9. Planning, control and discipline.
Cooke, Dr. R. (2012) Personal communication.
In addressing the particularly vexing challenge of
scale up (in Section 2), the authors have proposed Fourie, Prof A.B. (2012) Personal communication.
the following seven step solution:
Fourie, A.B. and Gawu, S.K.Y. (2010). The validity
1. Review published literature for evidence of of laboratory flume data for predicting beach
scale dependence for the parameter(s) under slopes of thickened tailings deposits. In: Paste
consideration. 2010, pp. 241-253, Toronto, Canada.
2. Recognize which parameters are scale
dependent, and which ones are not Simms, P., Fisseha, B., Henriquez, J. and Bryan,
3. Isolate the key parameters which are most R. (2009). Desiccation and rheology in cyclic
dependent on scale, researching their influence on surface deposition of gold paste tailings. In:
project parameters one at a time. Tailings and Mine Waste 08. Taylor & Francis
4. Attempt to describe in fundamental Group, London.
scientific terms or at the very least in empirical
terms, the nature of the influence of each key scale Morris, P. H. and Williams, D. J. (1996). Prediction
dependent parameter. of mine tailings delta profiles. Trans. Inst Min.
5. Establish the minimum scale of pilot test Metall. (Sect. A: Min. industry),
required to provide meaningful results, by a 105: A63-A68.
combination of research, fundamental analysis,
modeling and lab scale testing. Pirouz, B., Kavianpour, M.R., and Williams, P.
6. Explore the potential for increased (2005). Thickened tailings beach deposition. Field
understanding and characterization, by successive observations and full-scale flume testing. In: Paste
modelling at gradually increasing scales, while 2005, 20-22 April, Santiago, Chile, pp. 53-72.
tracking the change between stages
Tadepalli, S. (2009) Advances in Empirical
Similitude Method. Ph.D. Thesis, University of
Austin, Texas.

Web links:

http://en.wikipedia.org/wiki/Lubrication_theory

http://www.alice-in-
wonderland.net/books/1chpt6.html

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