Method and Device for In-Line Injection of Flocculent Agent into a Fluid Flow of Mature Fine Tailings

Abstract

A method and device for in-line injecting of flocculent agent into a fluid flow of mature fine tailings (MFT). The method includes the steps of: a) providing a fluid flow of mature fine tailings to be treated along a given channel fluidly connected to the pipeline; b) providing a source of flocculating agent; and c) introducing flocculating agent inside the fluid flow of mature fine tailings via a plurality of injection outlets for injecting the flocculating agent into the fluid flow in a dispersed manner so as to increase an exposed surface area of the injected flocculating agent and thus increase a corresponding reaction with the mature fine tailings, for an improved flocculation of said mature fine tailings, and/or other desired end results. Also disclosed is a kit with corresponding components for assembling the in-line injection device to be connected in-line with the pipeline carrying the mature fine tailings to be treated.

Claims

1-42. (canceled)

43. An in-line tailings flocculation system, comprising: a tailings feed pipeline configured to provide a flow of tailings and having an upstream end and a downstream end; an in-line flocculant injector for injecting a flocculation liquid containing a flocculating agent into the tailings, the in-line flocculant injector comprising: a sleeve comprising: a first end configured to be coupled to the downstream end of the tailings feed pipeline; a second end configured opposite the first end; and a side inlet in between the first and second ends and configured to receive a flow of the flocculation liquid; a tailings conduit defining a fluid passage therethrough and being mounted within the sleeve, the tailings conduit comprising: a frusto-conical segment that tapers inwardly in a downstream direction of the flow of tailings, the frusto-conical segment comprising: an upstream portion mounted to an inner surface of the first end of the sleeve and configured to receive the flow of tailings from the tailings feed pipeline; and a downstream portion located within the sleeve; a cylindrical segment having a wall thickness and comprising: an upstream section coupled to the downstream portion of the frusto-conical segment; a downstream section defining a tailings outlet; and a plurality of injection outlets through the wall thickness; a backing ring mounted about the tailings outlet of the cylindrical segment in between the cylindrical segment and the sleeve, such that the backing ring, the tailings conduit and the sleeve define therebetween an annular flocculant conduit that receives the flow of the flocculation liquid from the side inlet of the sleeve, the annular flocculant conduit being in fluid communication with the fluid passage via the injection outlets, such that the flocculation liquid is capable of flowing from the side inlet, through the annular flocculant conduit and out of injection outlets into the flow of the tailings in the fluid passage to form a flocculation material which is expelled via the tailings outlet; a downstream pipeline coupled to the second end of the sleeve being in fluid communication with the fluid passage of the tailings conduit so as to receive the flocculation material.

44. The in-line tailings flocculation system of claim 43, wherein the plurality of injection outlets comprises injection outlets that are arranged circumferentially about the cylindrical segment of the tailings conduit.

45. The in-line tailings flocculation system of claim 44, wherein the plurality of injection outlets comprises at least one opposed pair of injection outlets that are arranged on opposite lateral sides of the cylindrical segment.

46. The in-line tailings flocculation system of claim 44, wherein the plurality of injection outlets comprises at least one perpendicular pair of injection outlets that are arranged at ninety degrees with respect to each other.

47. The in-line tailings flocculation system of claim 43, wherein the injection outlets each have a circular cross-section.

48. The in-line tailings flocculation system of claim 43, wherein the frusto-conical segment and the cylindrical segment of the tailings conduit join at a connection point that is downstream of a centerline axis of the side inlet.

49. The in-line tailings flocculation system of claim 43, wherein the second end of the sleeve comprises a flange extending outward and configured to be coupled to a corresponding flange of the downstream pipeline to secure the sleeve thereto.

50. The in-line tailings flocculation system of claim 49, further comprising opposed first and second mounting components on either side of the flange to prevent axial movement of the flange.

51. The in-line flocculation system of claim 50, wherein the first mounting component comprises a lap ring on a downstream side of the flange and a nut on an upstream side of the flange.

52. The in-line flocculation system of claim 43, wherein the upstream portion of the frusto-conical segment is connected to an inner surface of the first end of the sleeve by a circumferential weld.

53. The in-line flocculation system of claim 43, wherein the downstream portion of the frusto-conical segment is connected to the cylindrical segment by a circumferential weld.

54. The in-line flocculation system of claim 43, wherein the injection outlets each have a cross-sectional size that is substantially smaller than a cross-section of the cylindrical segment.

55. The in-line flocculation system of claim 43, wherein the injection outlets each have a cross-sectional size that is substantially smaller than a cross-section of the side inlet.

56. An in-line flocculant injector for injecting a flocculation liquid containing a flocculating agent into a flow of tailings, comprising: a sleeve comprising: a first end configured to receive the flow of tailings; a second end downstream from the first end; and a side inlet in between the first and second ends and configured to receive a flow of the flocculation liquid; a tailings conduit defining a fluid passage therethrough and being mounted within the sleeve, the tailings conduit comprising: a reducer that tapers inwardly in a downstream direction of the flow of tailings and being mounted within the sleeve; an injection segment having a wall thickness and comprising: an upstream section coupled to a downstream portion of the reducer; a downstream section defining a tailings outlet; and a plurality of injection outlets through the wall thickness; wherein the tailings conduit and the sleeve define therebetween a flocculant conduit that receives the flow of flocculation liquid from the side inlet of the sleeve, the flocculant conduit being in fluid communication with the fluid passage via the injection outlets, such that the flocculation liquid is capable of flowing from the side inlet, through the flocculant conduit and out of injection outlets into the flow of the tailings in the fluid passage to form a flocculation material which is expelled via the tailings outlet.

57. The in-line flocculant injector of claim 56, wherein the reducer has a frusto-conical shape and the injection segment has a cylindrical shape.

58. The in-line flocculant injector of claim 56, further comprising a backing ring secured in between the second end of the sleeve and the downstream section of the injection segment, and the backing ring defines an end surface of the flocculant conduit.

59. The in-line flocculant injector of claim 58, wherein the flocculant conduit has an annular cross-sectional shape.

60. The in-line flocculant injector of claim 56, wherein the injection outlets each have a cross-sectional size that is substantially smaller than a cross-section of the cylindrical segment.

61. The in-line flocculant injector of claim 60, wherein the plurality of injection outlets comprises at least four injection outlets that are equally spaced apart about a circumference of the injection segment of the tailings conduit.

62. The in-line flocculant injector stem of claim 56, wherein the tailings conduit is centered within the sleeve along a longitudinal axis thereof that extends between the first and second ends.

63. The in-line flocculant injector of claim 56, wherein the reducer comprises side walls that define an acute angle with respect to a longitudinal axis extending along a centerline of the reducer.

64. The in-line flocculant injector of claim 56, wherein the tailings conduit is defined by side walls that define inner and outer continuous flat surfaces but for the injection outlets.

65. The in-line flocculant injector of claim 56, wherein the reducer is longer than the injection segment.

66. An in-line flocculant injector for injecting a flocculation liquid containing a flocculating agent into a flow of tailings, comprising: a sleeve comprising: a first end configured to receive the flow of tailings; a second end downstream from the first end; and a side inlet in between the first and second ends and configured to receive a flow of the flocculation liquid; a tailings conduit defining a fluid passage therethrough and being mounted within the sleeve, the tailings conduit comprising: a reducer mounted within the sleeve and configured to receive and accelerate the flow of tailings to provide a flowrate increased tailing flow; an injection segment having a wall thickness and comprising: an upstream section coupled to the reducer to receive the flowrate increased tailing flow therefrom; a downstream section defining a tailings outlet; and a plurality of injection outlets through the wall thickness; wherein the tailings conduit and the sleeve define therebetween a flocculant conduit that receives the flow of flocculation liquid from the side inlet of the sleeve, the flocculant conduit being in fluid communication with the fluid passage via the injection outlets, such that the flocculation liquid is capable of flowing from the side inlet, through the flocculant conduit and out of injection outlets into the flowrate increased tailing flow to form a flocculation material which is expelled via the tailings outlet.

67. The in-line flocculant injector of claim 66, wherein the reducer comprises side walls that taper inwardly in a downstream direction.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0057] FIG. 1 is a perspective view of an injection device according to a preferred embodiment of the present invention.

[0058] FIG. 2 is a perspective view of an inner component of the injection device shown in FIG. 1.

[0059] FIG. 3 is a perspective view of an outer component of the injection device shown in FIG. 1.

[0060] FIG. 4 is a front view of what is shown in FIG. 1.

[0061] FIG. 5 is a front view of what is shown in FIG. 2.

[0062] FIG. 6 is a cross-sectional view taken along line VI-VI of FIG. 4.

[0063] FIG. 7 is a schematic cross-sectional representation of a pipeline carrying a fluid flow of mature fine tailings and being provided with an injection device according to a preferred embodiment of the present invention.

[0064] FIG. 8 is a perspective view of an injection device according to another preferred embodiment of the present invention.

[0065] FIG. 9 is a perspective view of an inner component of the injection device shown in FIG. 8.

[0066] FIG. 10 is a perspective view of an outer component of the injection device shown in FIG. 8.

[0067] FIG. 11 is a front view of what is shown in FIG. 8.

[0068] FIG. 12 is a front view of what is shown in FIG. 9.

[0069] FIG. 13 is a cross-sectional view taken along line XIII-XIII of FIG. 11.

[0070] FIG. 14 is a schematic cross-sectional representation of a pipeline carrying a fluid flow of mature fine tailings and being provided with an injection device according to another preferred embodiment of the present invention.

[0071] FIG. 15 is a perspective view of an injection device according to yet another preferred embodiment of the present invention.

[0072] FIG. 16 is a perspective view of an inner component of the injection device shown in FIG. 15.

[0073] FIG. 17 is a perspective view of an outer component of the injection device shown in FIG. 15.

[0074] FIG. 18 is a front view of what is shown in FIG. 15.

[0075] FIG. 19 is a front view of what is shown in FIG. 16.

[0076] FIG. 20 is a cross-sectional view taken along line XX-XX of FIG. 18.

[0077] FIG. 21 is a schematic cross-sectional representation of a pipeline carrying a fluid flow of mature fine tailings and being provided with an injection device according to yet another preferred embodiment of the present invention.

[0078] FIG. 22 is a schematic representation of a pipeline intended to be used with at least one tailings pond and being provided with an injection device according to another preferred embodiment of the present invention.

[0079] FIG. 23 is an enlarged schematic representation of a portion of what is shown in FIG. 22, including the injection device being connected in-line with a pipeline of MFT and being connected to a source of flocculent agent.

[0080] FIG. 24 is a side view of an injection device according to yet another preferred embodiment of the present invention.

[0081] FIG. 25 is a top view of what is shown in FIG. 24.

[0082] FIG. 26 is a front elevational view of what is shown in FIG. 24.

[0083] FIG. 27 is an exploded view of the components of the injection device shown in FIG. 24.

[0084] FIG. 28 is a side elevational view of a reducer according to a preferred embodiment of the present invention.

[0085] FIG. 29 is a front view of what is shown in FIG. 28.

[0086] FIG. 30 is a rear view of what is shown in FIG. 28.

[0087] FIG. 31 is a front plan view of a ring according to a preferred embodiment of the present invention.

[0088] FIG. 32 is a cross-sectional view taken along line XXXI I-XXXII of FIG. 31.

[0089] FIG. 33 is a cross-sectional view taken along line XXXIII-XXXIII of the injection device of FIG. 26.

[0090] FIG. 34 is an enlarged sectional view of a portion of what is shown in FIG. 33.

[0091] FIG. 35 is an enlarged sectional view of another portion of what is shown in FIG. 33.

[0092] FIG. 36 is an enlarged sectional view of another portion of what is shown in FIG. 33.

[0093] FIG. 37 is an enlarged sectional view of another portion of what is shown in FIG. 33.

[0094] FIG. 38 is an enlarged sectional view of a rear portion of what is shown in FIG. 33.

[0095] FIG. 39 is a branch fitting of a pipeline carrying mature fine tailings and being provided with an injection device according to another preferred embodiment of the present invention.

[0096] FIG. 40 is a branch fitting of a pipeline carrying mature fine tailings and being provided with an injection device according to yet another preferred embodiment of the present invention.

[0097] FIG. 41 is a side view of the injection device shown in FIG. 40.

[0098] FIG. 42 is an enlarged view of a distal front portion of the injection device of FIG. 41.

[0099] FIG. 43 is a sectional view of a portion of what is shown in FIG. 42.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0100] In the following description, the same numerical references refer to similar elements. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures are preferred, given for exemplification purposes only.

[0101] Moreover, although the present invention was primarily designed for injecting flocculent agent, such as liquid polymer for example, into a fluid flow of a pipeline carrying mature fine tailings (MFT) for example, it may be used with other types of substance(s) and/or liquid(s), for other purposes, and in other fields, as apparent to a person skilled in the art. For this reason, expressions such as “injecting”, “flocculent”, “agent”, “liquid, “polymer”, “pipeline”, “MFT”, etc. used herein should not be taken as to limit the scope of the present invention and includes all other kinds of pipelines, cylinders, items and/or applications with which the present invention could be used and may be useful.

[0102] Moreover, in the context of the present invention, the expressions “device”, “kit”, “unit”, “apparatus”, “mechanism”, “assembly”, “spool”, “system”, “set” and any other equivalent expression and/or compound word thereof known in the art will be used interchangeably. Furthermore, the same applies for any other mutually equivalent and/or complementary expressions, such as “pipeline”, “cylinder”, “conduit”, “channel”, and “pipe”, as well as “additive”, “solution” and “agent” for example, or even “flocculent”, “chemical” and “reactive”, as well as “co-annularly”, “co-axially”, “concentrically”, “conjointly” and “complementary”, as also apparent to a person skilled in the art. The same can be said about other similar expressions such as “processing”, “mixing”, “treating”, solidifying”, “dewatering”, “flocculating” and “consolidating”, or even “outlet”, “orifice” and “hole”, as also apparent to a person skilled in the art.

[0103] In addition, although the preferred embodiment of the present invention as illustrated in the accompanying drawings comprises various components and although the preferred embodiment of the injecting device as shown consists of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential to the invention and thus should not be taken in their restrictive sense, i.e. should not be taken as to limit the scope of the present invention. It is to be understood that other suitable components and cooperations thereinbetween, as well as other suitable geometrical configurations may be used for the injecting device and corresponding parts according to the present invention, as well as corresponding conversion kit or set, and/or resulting pipeline or circuit, as briefly explained herein, or as can be easily inferred herefrom, by a person skilled in the art, without departing from the scope of the present invention.

[0104] Broadly described, the present invention, as exemplified and shown in the accompanying drawings, relates to an improved method of introducing flocculating agent into a fluid flow of a pipeline carrying mature fine tailings in order to improve reaction of the flocculating agent with said mature fine tailings for an improved flocculating of the mature fine tailings, and/or corresponding resulting advantages, such as dewatering, for example. This new method of in-line injection of flocculating agent into a pipeline of mature fine tailings distinguishes itself from other known techniques in that the introduction of flocculating agent is done inside the fluid flow of mature fine tailings via a plurality of injection outlets for injecting the flocculating agent into the fluid flow in a “dispersed manner”, so as to increase a wetted perimeter and thus an exposed surface area of the injected flocculating agent, in order to increase a corresponding reaction with the mature fine tailings, for improved end results. The present invention also relates to a corresponding injection device for in-line connection with the pipeline carrying the mature fine tailings, and in order to carry out the in-line injection method according to the present invention.

LIST OF NUMERICAL REFERENCES FOR SOME OF THE CORRESPONDING PREFERRED COMPONENTS ILLUSTRATED IN THE ACCOMPANYING DRAWINGS

[0105] 1. injection device [0106] 3. flocculent agent [0107] 5. fluid flow [0108] 7. pipeline [0109] 9. mature fine tailings [0110] 11. main inlet [0111] 13. main channel [0112] 15. main outlet [0113] 17. complementary conduit [0114] 19. feed inlet [0115] 21. injection outlet [0116] 21c. center point (of injection outlet 21) [0117] 23. inner surface (of main conduit 13) [0118] 25. connecting flange (of feed inlet 19) [0119] 27. inner component [0120] 29. cylinder [0121] 31. first end (of cylinder 29) [0122] 33. second end (of cylinder 29) [0123] 35. ring (of cylinder 29) [0124] 37. outer component [0125] 39. sleeve [0126] 41. first end (of sleeve 39) [0127] 43. first flange (of first end 41) [0128] 45. first section (of pipeline 7) [0129] 47. second end (of sleeve 39) [0130] 49. second flange (of first end 47) [0131] 51. second section (of pipeline 7) [0132] 53. peripheral surface (of sleeve 39) [0133] 55. transitional segment [0134] 57. interface segment [0135] 59. main segment [0136] 61. longitudinal axis (of fluid flow 5) [0137] 63. tee joint [0138] 65. first section (of tee joint 63) [0139] 65a. orifice (of first section 65) [0140] 67. second section (of tee joint 63) [0141] 67a. orifice (of second section 67) [0142] 69. third section (of tee joint 63) [0143] 69a. orifice (of third section 69) [0144] 71. first flange [0145] 73. second flange [0146] 75. third flange [0147] 77. reducer [0148] 79. inlet (of reducer 77) [0149] 81. outlet (of reducer 77) [0150] 83. inner pipe [0151] 85. inlet (of inner pipe 83) [0152] 87. outlet (of inner pipe 83) [0153] 89. outer pipe [0154] 91. backing ring [0155] 93. lap ring [0156] 95. nut [0157] 97 lateral pipe fitting [0158] 99 main line (of lateral pipe fitting 97) [0159] 101 branch line (of lateral pipe fitting 97) [0160] 103 abutment flange [0161] 105 distal end (of branch line 101) [0162] 107 supporting body [0163] 109 internal conduit [0164] 111 distal extremity (of supporting body 107) [0165] 113 stabilizer

[0166] As previously explained, and according to a preferred aspect of the present invention, there is provided an injection device (1) for in-line injection of flocculating agent (3) into a fluid flow (5) of a pipeline (7) of mature fine tailings (9) in order to promote reaction of the flocculent agent (3) with the mature fine tailings (9). As exemplified in the accompanying drawings, and more particularly in FIGS. 1-21, the injection device (1) comprises a main inlet (11), a main channel (13), a main outlet (15), and a complementary conduit (17). The main inlet (11) is intended for receiving the fluid flow (5) of the pipeline (7) carrying mature fine tailings (9), and the main channel (13) is where the fluid flow (5) entering the inlet (11) is allowed to travel. The fluid flow (5) circulating through the pipeline (7) and thus through the injection device (1) which is connected in-line to the pipeline (7) is then allowed to be released out from the main outlet (15) of the injection device (1). An innovative aspect of the injection device (1) resides namely in its complementary conduit (17), which, as better exemplified in FIGS. 6, 13 and 20, is preferably disposed co-annularly (or co-axially, conjointly, etc.) with respect to the main channel (13), and configured for receiving flocculent agent (3) from a feed inlet (19), typically different from the main inlet (11), and has a plurality of injection outlets (21) disposed about the main outlet (15) for injection flocculating agent (3) into the fluid flow (5) exiting the main outlet (15), the injection outlets (21) being shaped and sized, and each having an orifice substantially smaller than that of the feed inlet (19) so as to increase dispersion of the flocculent agent (5) about the main outlet (15) in order to improve mixing of the fluid flow (5) with said flocculent agent (3) via an increased exposed surface area of the flocculent agent (3), thus overcoming several of the drawbacks and inconveniences associated with mixing techniques associated with the prior art.

[0167] As will be explained in greater detail hereinbelow, it is worth mentioning that, according to the present invention, the injection outlets (21) for introducing the flocculating agent (3) into the fluid flow (5) of mature fine tailings (9) in a dispersed manner may be positioned at different locations, and advantageously, accordingly within the injection device (1) and/or pipeline (7) so as to benefit from certain dynamic behavior within the fluid flow (5) of the mature fine tailings (9), in order to obtain an improved reaction of the flocculating agent (3) with the mature fine tailings (9).

[0168] According to one aspect of the present invention, the injection device (1) is preferably configured so that the main inlet (11) thereof be tapered, namely so that fluid flow (5) from the pipeline (7) carrying mature fine tailings (9) entering the injection device (1) goes through a reduced cross-sectional area in order to increase the velocity of the fluid flow (5), and in turn obtain a resulting turbulence within the fluid flow (5) which could advantageously be used when the flocculating agent (3) is introduced into the fluid flow (5) in a dispersed manner, via the plurality of injection outlets (21), whether directly into such a turbulent zone of the fluid flow (5), or downstream thereof (and in some cases, even “upstream”), for optimizing the introduction, mixing and/or reaction of the flocculating agent (3) with the mature fine tailings (9).

[0169] Preferably, and as can be easily understood by a person skilled in the art, although the injection device (1) according to the present invention could be used with a main inlet (11) having a cross-sectional area which changes abruptly along the channel, for increasing rapidly the flow velocity of the mature fine tailings (9) traveling therealong, the main inlet (11) for the injection device (1) according to a preferred embodiment of the present invention is preferably gradually tapered so as to progressively increase the flow velocity of the mature fine tailings (9), while attempting to minimize pressure loss of the fluid flow (5) travelling through said transitional segment (55) given that any pressure losses throughout the pipeline (7) are cumulative. For indicative purposes only, and according to a preferred embodiment of the present invention, the taper may range anywhere between about 7 degrees and about 90 degrees, depending on the particular application(s) for which the present injection device (1) is intended for, and the desired end result(s), as apparent to a person skilled in the art.

[0170] Moreover, it is worth mentioning also that providing a tapered main inlet (11) ensures that less wear will be caused onto the given component of the injection device (1) which provides such a main inlet (11), due to the nature of the mature fine tailings (9) which would normally damage or wear out an internal component of the main inlet (11) in a much faster manner if a change in the cross-sectional area was more abrupt, as can be easily understood by a person skilled in the art.

[0171] Referring more specifically to given preferred embodiments of the present invention, as exemplified in FIGS. 1-21, there is shown how the injection outlets (21) are preferably radially positioned about the main outlet (15) of the fluid flow (5) in an equally spaced manner. More specifically, according to these particular embodiments, the injection outlets (21) are provided about a backing ring (91) at the outermost rear part of the injection device (1). According to these particular embodiments, the injection device (1) preferably comprises eight injection outlets (21), each being about ⅞ inches in diameter, with a center point (21c) for each injection outlet (21) being positioned about ⅞ inches away from an inner surface (23) of the main channel (13), as better shown in FIGS. 5, 12 and 19. However, it is worth mentioning, as can also be easily understood by a person skilled in the art, that an important aspect of the present invention resides in the manner in which the flocculent agent (3) is introduced or “dispersed” within the fluid flow (5) of the mature fine tailings (9) for increasing a proper reaction, thus, the number of injection holes (21), the cross-sectional configuration thereof, the positioning with respect to the main channel (13), and other considerations, may be changed, altered and/or modified, depending on the particular applications for which the injection device (1) is intended for, the type of fluid flow (5) with which it is used, and the desired end results. It is worth mentioning however that irrespectively of the total number of injection outlets (21), whether two, three, four, five, six, seven, eight or more, the total area of the injection outlets (21) are preferably set to be less than the total flow area of the feed inlet (19) of flocculent agent (3), thereby ensuring that the injection outlet (21) is the primary pressure drop point which jets the solution (i.e flocculating agent (3)) into the MFT, for improved mixing.

[0172] According to one preferred aspect of the present invention, and based on certain tries having been carried out for optimizing the process, the increased wetted perimeter of the flocculating agent (3) being injected out through the injection outlets (21) is preferably about 2.8. However, it is worth mentioning also that such a ratio may vary once again, depending on the particular application(s) for which the present injection device (1) is intended for, and the desired end result(s), and that, in some cases, the exposed area for the polymer when dispersed to micro drops can be much higher, as can be easily understood by a person skilled in the art (ex. using simulation modeling, etc.). Preferably also, and according to another preferred embodiment, the main channel (13) is selected so as to have an internal diameter which is about half the size of an internal diameter of the pipeline (7). Indeed, as will be better described hereinbelow, the present injection device (1) has been designed so as to facilitate assembling and/or manufacturing thereof, with standard or readily available “off-the-shelf” components, while providing for a resulting innovative injection device (1) which enables to introduce the flocculating agent (3) into the fluid flow (5) of mature fine tailings (9) in an improved manner, for improved mixing end results.

[0173] Thus, it can be appreciated that, for example, an internal diameter of the main channel (13) could be about 6 inches, or even 4 inches, for a pipeline (7) having an internal diameter of about 12 inches. Furthermore, and as can be easily understood when referring to FIGS. 1-21, the feed inlet (19) of the injection device (1) is preferably provided with a connecting flange (25) for removably connecting the feed inlet (19) to a source of flocculating agent (3), or any other type of chemical reactive intended to cooperate with the mature fine tailings (9) circulating through the pipeline (7) for a corresponding flocculation, dewatering, or any other suitable intended purpose, as can be easily understood by a person skilled in the art.

[0174] According to one preferred embodiment, the flocculating agent (3) is a liquid polymer, designed for proper reaction with the mature fine tailings (9), but any other suitable substance, agent, chemical reactive, solution, and/or the like, may be used with the injection device (1), as can be easily understood by a person skilled in the art. It is worth mentioning as is well known in the art that MFT mainly consists of water, sand and clay, in which the solids content in the MFT can range anywhere between about 15-50%. Typical injectors are essentially ineffective on MFT with a solids content greater than 30%, which is about greater or equal to about 1.22 specific gravity. However, the present injection device (1) and corresponding components (injection outlets (21), etc.) are designed to work equally well throughout the full range of MFT solids contents, and this characteristic of the injection device (1) is an important reason for its design and implementation into the MFT drying system.

[0175] Referring to FIGS. 1-21, there is shown how according to a given aspect of the present invention, the injection device (1) can be assembled using an inner component (27), and an outer component (37). The inner component (27) preferably comprises a cylinder (29) defining the main channel (13) along which the fluid flow (5) is allowed or intended to travel, the cylinder (29) having a first end (31) operatively connectable to the main inlet (11) and a second end (33) provided with a ring (35) operatively connectable to the main outlet (15), the ring (35) being provided with the injection outlets (21).

[0176] Referring now to the outer component (37), it preferably comprises a sleeve (39) concentrically mounted about the inner component (27), the sleeve (39) having a first end (41) provided with a first flange (43) being removably connectable onto a first section (45) of the pipeline (7), and a second end (47) provided with a second flange (49) being removably connectable onto a second section (51) of the pipeline (7) for in-line connection of the injection device (1) with the pipeline (7), the outer component (37) being also provided with the feed inlet (19) projecting outwardly from a peripheral surface (53) of the sleeve (39), as better shown in FIGS. 3, 10 and 17.

[0177] As can be easily understood when referring to FIGS. 6, 13 and 20, the cylinder (29) and the sleeve (39) are preferably configured so that the complementary conduit (17) is defined thereinbetween when the outer component (37) is mounted about the inner component (27), the complementary conduit (17) being in fluid communication between the feed inlet (19) and the injection outlets (21) provided on the ring (35) of the inner component (27) so that flocculating agent (3) introduced into the complementary conduit (17) via the feed inlet (19) is injected out the injection outlets (21) of the inner component (27) so as to increase dispersion of the flocculating agent (3) within the fluid flow (5), as can be easily understood when referring to FIGS. 7, 14 and 21.

[0178] Similarly to what was described earlier, the first end (31) of the cylinder (29) of the inner component (27) is preferably tapered, in a gradual manner. Advantageously, and preferably also, the outer component (37) consists of a standard fitting, for facilitating procurement and assembling of the components of the injection device (1). For example, the first and second ends (31,33) of the cylinder (29) can respectively be welded onto the first and second ends (41,47) of the sleeve (39), as can be easily understood when referring to FIGS. 6, 13 and 20, although other suitable ways of assembling, affixing and/or securing the various components of the injection device (1) are also intended with the present invention, as can be easily understood by a person skilled in the art.

[0179] Although different variations of possible in-line injection devices (1) have been explained and illustrated in the present description, it is worth mentioning that an important aspect of the present invention resides in the provision of a new method for in-line injection of flocculating agent (3) into a pipeline (7) of mature fine tailings (9) in order to promote flocculation of said mature fine tailings (9) and obtain other resulting advantages, as can be easily understood by a person skilled in the art. The method preferably comprises the steps of: a) providing a fluid flow (5) of mature fine tailings (9) to be treated along a given channel fluidly connected to the pipeline (7); b) providing a source of flocculating agent (3); and c) introducing flocculating agent (3) inside the fluid flow (5) of mature fine tailings (9) via a plurality of injection outlets (21) for injecting the flocculating agent (3) into the fluid flow (5) in a dispersed manner so as to increase an exposed surface area of the injected flocculating agent (3) and thus increase a corresponding reaction with the mature fine tailings (9), for an improved flocculation of the mature fine tailings (9), and/or other resulting advantages. As apparent to a person skilled in the art, the manners in which this method and corresponding injection device (1) could be used are various.

[0180] For example, step c) could comprise the step of i) creating a zone of turbulence within the fluid flow (5) of mature fine tailings (9); and ii) injecting flocculating agent (3) in a dispersed manner via the plurality of injection outlets (21) within said zone of turbulence for mixing the flocculating agent (3) with the mature fine tailings (9) and further promoting flocculation of the mature fine tailings (9).

[0181] Step a) of the present invention could also comprise the step of iii) reducing the cross-sectional area of the channel along a given transitional segment (55) of the channel for increasing the flow velocity of the mature fine tailings (9) travelling through said transitional segment (55), and in turn increasing a turbulence of the fluid flow (5) exiting form the transitional segment (55), as can be easily understood when referring to FIGS. 7, 14 and 21.

[0182] Step a) of the present invention could also comprise the step of gradually reducing the cross-sectional area of the channel along a given slope, which in some of the embodiments illustrated in the accompanying drawings, preferably has a ratio of about 7 to 1, as better shown in FIG. 33 for example, so as to namely, and as previously explained, prevent a pressure loss of the fluid flow (5) travelling through said transitional segment (55).

[0183] It is worth mentioning also that step a) of the present invention could also comprise the step of iv) rapidly increasing the cross-sectional area of the channel along a given interface segment (57) of the channel for abruptly altering the flow velocity of the mature fine tailings (9) travelling through said interface segment (57) of the channel, in order to create a turbulent zone of fluid flow (5) adjacent to said interface segment (57). As can be easily understood by a person skilled in the art, this abrupt change in cross-sectional area of the fluid flow (5) is done when the fluid flow (5) exits the main channel (13) of the injection device (1) and flows back into the pipeline (7) at the second section (51) thereof, as schematically represented in FIGS. 7, 14 and 21.

[0184] According to one aspect of the present invention, step c) of the method could comprise the step of positioning the injection outlets (21) about the main segment (59) of the channel so that the flocculating agent (3) is injected radially towards a longitudinal axis (61) of the fluid flow (5), as exemplified in FIG. 38.

[0185] Alternatively, or additionally, step c) could also comprise the step of positioning the injection outlets (21) about an interface segment (57) of the channel so that the flocculating agent (3) is injected in a direction substantially parallel to a longitudinal axis (61) of the fluid flow (5), as exemplified in FIGS. 7, 14 and 21.

[0186] Preferably, and for improved reactive purposes, the flocculating agent (3) is injected through the plurality of injection outlets (21) into a turbulent zone created and defined adjacent to said interface segment (57), so that the flocculating agent (3) may react advantageously due to its dispersion via a plurality of injection outlets (21), which provide for an increased exposed surface area, and thus resulting improved reaction, in addition to being injected in a zone of turbulence which could also further add to the improved reaction with the mature fine tailings (9).

[0187] According to another aspect of the present invention, and as can be easily understood when referring to FIGS. 24-38, there is also provided a kit for assembling an injection device (1) for in-line injection of flocculating agent (3) into a fluid flow (5) of a pipeline (7) of mature fine tailings (9). The kit may comprise a tee joint (63) (or simply t-joint (63)), a first flange (71), a second flange (73), a third flange (75), a reducer (77) and an inner pipe (83).

[0188] Preferably, and as better shown in FIGS. 24-27, the t-joint (63) has first, second and third sections (65,67,69), each section (65,67,69) being provided with the corresponding orifice (65a,67a,69a) being fluidly connected to each other. The first flange (71) is preferably mountable about the first section (65) of the t-joint (63), and is configured for mounting the assembled injection device (1) onto a first section (45) of the pipeline (7), as exemplified in FIGS. 22 and 23. The second flange (73) is preferably mountable about the second section (67) of the t-joint (63), and is configured for mounting the assembled injection device (1) onto a second section (51) of the pipeline (7). The third flange (75) is preferably mountable about the third section (69) of the t-joint (63), and is configured for connecting the assembled injection device (1) to a source of flocculating agent (3), as represented schematically in FIG. 23.

[0189] The reducer (77) of the kit is preferably mountable onto the first section (65) of the t-joint (63) so as to be positioned inside the t-joint (63), as better shown in FIG. 27, and the reducer (77) has an inlet (79) and an outlet (81), the inlet (79) of the reducer (77) being concentrically mountable about the orifice (65a) of the first section (65) of the t-joint (63), the cross-sectional area of the reducer (77) being reduced from its inlet (79) to its outlet (81), for obtaining corresponding resulting advantages, as briefly described hereinabove.

[0190] Referring now to FIG. 38, and as can be easily understood, the inner pipe (83) is preferably mountable onto the second section (67) of the t-joint (63) so as to be positioned inside the t-joint (63), the inner pipe (83) having an inlet (85) and an outlet (87), the inlet (85) of the inner pipe (83) being connectable to the outlet (81) of the reducer (77), the outlet (87) of the inner pipe (83) being concentrically mountable about the orifice (67a) of the second section (67) of the t-joint (63), the inner pipe (83) being cooperable with the second section (67) of the t-joint (63) for defining a plurality of injection outlets (21) about the outlet (87) of the inner pipe (83) so that flocculating agent (3) coming from the third section (69) of the t-joint (63) be injected in a dispersed manner through said injection outlets (21) and into the fluid flow (5) of mature fine tailings (9) travelling through the reducer (77) and the inner pipe (83). As previously explained, and according to a preferred aspect of the present invention, the injection outlets (21) may be provided about different suitable locations within the injection device (1), whether it be directly about the inner pipe (83), or provided about a corresponding ring (35).

[0191] According to a given preferred embodiment, the second section (67) of the t-joint (63) preferably includes an outer pipe (89) positionable concentrically about the inner pipe (83) for defining a conduit (17) thereinbetween destined to receive the flocculated agent (3), as can be easily understood when referring to FIGS. 33 and 38. Preferably also, the second flange (73) is mountable onto the outer pipe (89), and the kit further comprises a backing ring (35,91) mountable between the inner pipe (83) and the outer pipe (89). The backing ring (91) may be provided with injection outlets (21) for receiving flocculating agent (3) from the second section (67) of the t-joint (63), and for injecting the flocculent agent (3) into the fluid flow (5) in a dispersed manner, as can be easily understood when referring to the preferred embodiments of the present invention illustrated in FIGS. 1-21.

[0192] According to another aspect, the kit may also comprise a lap ring (93) mountable onto the second flange (73), as well as a nut (95) mountable onto the second flange (73), and as can be easily understood when referring to FIGS. 27, 33 and 38, the components of the kit operatively secured onto one another in a suitable manner, and preferably, by an appropriate assembling or connecting method, such by welding, for example.

[0193] It is worth mentioning that various other suitable injection devices (1) may be provided for carrying out the injection method according to the present invention. For example, when referring to FIGS. 39-43, there is shown how according to a given preferred embodiment, the injection device (1) according to the present invention may also be provided in a form of an injection device (1) for use with a lateral pipe fitting (97) of a pipeline (7) of mature fine tailings (9), the lateral pipe fitting (97) having a substantially y-joint arrangement including a main line (99) along which a fluid flow (5) of mature fine tailings (9) is intended to travel, and a corresponding branch line (101). The injection device (1) may comprise an abutment flange (103) for abutting against a distal end (105) of the branch line (101). The injection device (1) may also comprise a supporting body (107) projecting from the abutment flange (103) inwardly towards the main line (99), the supporting body (107) having an internal conduit (109) for conveying flocculent agent (3) to be introduced into the fluid flow (5) via a corresponding distal extremity (111) (or “end portion”) intersecting the fluid flow (5) of mature fine tailings (9). The injection device (1) also preferably comprises a plurality of injection outlets (21) provided on the distal extremity (111) (i.e. “end portion”) of the supporting body (107), and through which flocculent agent (3) is injected, the injection outlets (21) being shaped and sized, and each having an orifice substantially smaller than that of the internal conduit (109) so as to increase dispersion of the flocculating agent (3) about the injection outlets (21) in order to improve mixing of the fluid flow (5) with said flocculating agent (3) via an increased exposed surface area of the flocculating agent (3) provided by the plurality of injection outlets (21).

[0194] According to a first preferred embodiment, as better shown in FIG. 39, the supporting body (107) of the injection device (1) is configured so that its distal extremity (111) is positioned about a main longitudinal axis (61) of the fluid flow (5), and so that injection outlets (21) are positioned substantially below said longitudinal axis (61).

[0195] According to another preferred embodiment, as better shown in FIG. 40, the supporting body (107) of the injection device (1) is configured so that its distal extremity (111) is positioned above a main longitudinal axis (61) of the fluid flow (5), and so that injection outlets (21) are substantially positioned about said longitudinal axis (61).

[0196] The supporting body (107) may simply be a cylinder or a pipe, and according to a given embodiment, as better shown in FIGS. 42 and 43, the injection outlets (21) are disposed about the supporting body (107) along four rows of injection outlets (21), with about 30 degrees of radial separation between each row of injection outlets (21), and most of the injection outlets (21) being about ⅜ inches in diameter. Preferably also, the internal conduit (109) of the supporting body (107) is about ¾ inches in diameter. Once again, it is worth mentioning, as can also be easily understood by a person skilled in the art, that an important aspect of the present invention resides in the manner in which the flocculent agent (3) is introduced or “dispersed” within the fluid flow (5) of the mature fine tailings (9) for increasing a proper reaction, thus, the number of injection holes (21), the cross-sectional configuration thereof, the number of rows of said injections holes (21), the positioning with respect to the main channel (13) or internal conduit (109), and other considerations, may be changed, altered and/or modified, depending on the particular applications for which the injection device (1) is intended for, the type of fluid flow (5) with which it is used, and the desired end results.

[0197] The supporting body (107) is preferably provided with a stabilizer (113) for resting against an inner wall of the branch line (101), which enables namely to maintain the distal extremity (111) of the injection device (1) substantially fixed with respect to the fluid flow (5), thereby minimizing vibrations to said distal extremity (111), etc., as can be easily understood by a person skilled in the art.

[0198] Finally, and according to the present invention, the injecting device (1) and corresponding parts are preferably made of substantially rigid materials, such as metallic materials (stainless steel, etc.), hardened polymers, composite materials, and/or the like, whereas other components thereof according to the present invention, in order to achieve the resulting advantages briefly discussed herein, may preferably be made of a suitably malleable and resilient material, such as a polymeric material (plastic, rubber, etc.), and/or the like, depending on the particular applications for which the injecting device (1) and resulting pipeline (1) or closed circuit are intended for and the different parameters in cause, as apparent to a person skilled in the art.

[0199] Furthermore, the present invention is a substantial improvement over the prior art in that, by virtue of its design and components, the device (1) is simple and easy to use, as well as is simple and easy to manufacture and/or assemble, and provides for a much more efficient and cost effective manner of processing MFT.

[0200] Indeed, as may now be better appreciated, the present invention is substantially advantageous over conventional techniques in that it allows for a much faster and more efficient mixing of liquid polymer with the mature fine tailings (MFT), namely due to the fact that the flocculating agent (for example, liquid polymer) is introduced into the fluid flow of mature fine tailings in a dispersed manner via a plurality of injection outlets. This enables namely a lower polymer usage for the same quantity of MFT as compared to an un-optimized design. Moreover, this enables for increased process efficiency.

[0201] The present invention is also advantageous in that it allows for very low maintenance on a device and fabrication can be completed in-house, with straightforward “off-the-shelf” components, as briefly explained hereinabove.

[0202] As may also now be better appreciated, the solution proposed with the present invention is also advantageous in that it introduces liquid polymer into the MFT at a higher velocity through multiple openings, thus increasing the exposed surface area of the liquid polymer. In contrast, conventional techniques minimize exposed surface area of the polymer which leaves a large amount of polymer unmixed, with associated drawbacks and inconveniences. It is worth mentioning also that according to the present invention, the design of the injection spool also promotes a turbulent zone near the point of injection which aids in rapidly mixing the dispersed polymer. Thus, there is an increased contact area between the polymer and the MFT at the injection point. Moreover, and as explained earlier, the design of the injector spool promotes a turbulent zone at the area of injection which promotes rapid mixing of MFT and polymer. Typically, with an inefficient injection device, excess polymer is added to compensate for the poor injection, whereas the present new and innovative design enables to make up for the inefficiency and polymer usage can be minimized.

[0203] Indeed, an important aspect of the present invention resides in that instead of polymer injection into the MFT stream via a large opening, as is normally done in the prior art, polymer injection is done through multiple holes of smaller diameter achieving the same or even greater overall injection velocity but significantly increasing the exposed polymer surface area, for an improved reactive process and improved end results.

[0204] As previously explained, and according to one preferred embodiment of the present invention, the present injection device reduces the 12 inch MFT flow down to a 6 inch flow through a concentric reducer. The flow is then dramatically expanded from 6 inches back to 12 inches creating a turbulent zone. This zone is the location where preferably polymer injection holes are provided, for the injection of the liquid polymer. This provides adequate contact area for the polymer while also providing extra mixing of the two fluids. In the present case, mixing takes place directly at the injection point which is positioned and placed accordingly, for optimal results. Because the injection of the polymer is optimized, the mixture subsequently enters the drying cell with the greatest potential for immediate water release and optimal drying times, two process requirements for MFT drying.

[0205] It is worth mentioning also that fabrication of the present injection device (1) is fairly simple to carry out, in that, according to a preferred embodiment, it may simply involve a standard t-fitting with standard steel parts inside of minimal complexity. Therefore, it can economically be fabricated, with relatively readily available off-the-shelf components. Furthermore, the present invention is also advantageous in that the maintenance of the injection device (1) is fairly minimal as the component is essentially run to failure with surface wear being the failure mechanism. Because the service is MFT, the wear rates are much lower than with coarse tailings.

[0206] Various other variations or alternatives of the present invention could be made, as apparent to a person skilled in the art. For example, it has been explained that once the injection location is chosen, the device (1) can be installed in-line with standard flange connections. This is typically done on a 12 inch MFT pipeline. The polymer inlet is thus typically 8 inch and can also be connected to the device via a standard 8 inch flange inlet. However, it is worth mentioning that various other barometers or design variables could be considered for the present invention in that for example, one of them could be the reduction of the internal pipe from 6 inch to 4 inch. Indeed, the subsequent turbulent zone becomes larger and it is thought that this can aid in mixing during times where the feed density dictates such a change. It is also worth mentioning that standard flange connections provide for easy installation, and that for particular applications, expansion from 6 inch internal diameter to 12 inch provides a turbulent zone whereby extra mixing is induced into the injection area.

[0207] Moreover, it is worth mentioning also, that although the main outlet (15) of the present injection device (1) has been exemplified in the accompanying drawings as being substantially “vertical”, such an outlet (15) may deviate from a vertical plane, at a given angle, for example, within a range of about 10 degrees relative to the horizontal up to vertical. Indeed, a person skilled in the art may appreciate that while mechanical construction of the vertical unit is easier, an appropriate angle of the outlet (15) promotes some recovery of the pressure while mixing the fluids. Therefore, one can view the injection orifices (21) shown in FIG. 33 as being a 0-degree case. Furthermore, a person skilled in the art will also understand that the fact of having sharp-edged or rounded-edged injection orifices (21) will affect the flow rate through the nozzle. Sharp edges are easiest to drill, while tapered or rounded edges provide better flow capacity. Thus, in addition to the various changes that could be made to the present injection device (1), not only the shape and the positioning of the injection outlets (21) can be varied depending on different application(s) for which the injection device (1) is intended for, and the desired end result(s), but it is important to note also that the injection outlets (21) are not necessarily limited to “round” configurations or cross-sections, although they are easier to manufacture by simple drilling, punching, and the like, and that these very same injection outlets (21) or orifices can be made to take on various other suitable geometric configurations, and cross-sectional shapes, such as “star-like” configurations, for example, so as to further increase the exposed surface area (or “wetted perimeter”) of the flocculating agent (3) introduced into the fluid flow (5) by means of said injection outlets (21), as also apparent to a person skilled in the art.

[0208] Of course, numerous other modifications could be made to the above-described embodiments without departing from the scope of the invention, as defined in the appended claims.