Dual-packer injection leaching system and method
12291953 ยท 2025-05-06
Inventors
Cpc classification
E21B43/305
FIXED CONSTRUCTIONS
E21B43/28
FIXED CONSTRUCTIONS
International classification
E21B43/28
FIXED CONSTRUCTIONS
E21B19/22
FIXED CONSTRUCTIONS
E21B33/124
FIXED CONSTRUCTIONS
Abstract
A dual packer injection leaching system with a dual packer assembly and a support structure. The dual packer assembly has an upper packer, a lower packer, and a high dispersion screen disposed between the upper packer and the lower packer. The dual packer assembly is configured to be disposed within a borehole in a leach pile. The support structure is configured to support the dual packer assembly within the borehole. A wire rope couples the support structure to the dual packer assembly. A pneumatic line is configured to inflate the upper packer and the lower packer, and an injection line is configured to provide leachate solution through the high dispersion screen. The dual packer assembly is configured to deliver the leachate solution through the high dispersion screen to an interval of the borehole bounded by the upper packer and the lower packer.
Claims
1. A dual packer injection leaching system, comprising: a dual packer assembly configured to be disposed inside a well casing within a borehole in a leach pile, the dual packer assembly comprising a first upper packer, a first lower packer, and a first dispersion screen disposed between the first upper packer and the first lower packer, and a second upper packer, a second lower packer, and a second dispersion screen disposed between the second upper packer and the second lower packer; a crane hook configured to support the dual packer assembly during installation of the dual packer assembly inside the well casing; a mobile deployment system configured to be disposed adjacent the borehole, the mobile deployment system comprising: a wire rope coiled around a wire rope reel drum, the wire rope further coupled to the dual packer assembly, and a hose reel drum comprising a pneumatic line and an injection line, the pneumatic line coupled to the first upper packer and the first lower packer and the second upper packer and the second lower packer and configured to inflate the first upper packer and the first lower packer and the second upper packer and the second lower packer, and the injection line configured to provide leachate solution through the first dispersion screen and the second dispersion screen; and a support structure coupled to a chain hoist, the chain hoist coupled to the dual packer assembly and configured to support the dual packer assembly and provide for a release of the crane hook from the dual packer assembly; wherein the dual packer assembly is configured to deliver the leachate solution through the first dispersion screen to a first interval of the borehole bounded by the first upper packer and the first lower packer and through the second dispersion screen to a second interval of the borehole, the second interval lower than the first interval within the borehole and bounded by the second upper packer and the second lower packer.
2. The dual packer injection leaching system of claim 1, further comprising the wire rope, the injection line, and the pneumatic line coupled together with plastic ties placed at intervals of 3 meters or less.
3. The dual packer injection leaching system of claim 1, further comprising a leachate solution sprinkler system coupled to the injection line and configured to supply leachate solution to the injection line.
4. The dual packer injection leaching system of claim 1, wherein the borehole extends into the leach pile at an incline.
5. A dual packer injection leaching system, comprising: a dual packer assembly configured to be disposed inside a borehole in a leach pile, the dual packer assembly comprising a first upper packer, a first lower packer, and a first dispersion screen disposed between the first upper packer and the first lower packer, and a second upper packer, a second lower packer, and a second dispersion screen disposed between the second upper packer and the second lower packer; and a hose reel drum comprising a pneumatic line and an injection line, the pneumatic line coupled to the first upper packer and the first lower packer and the second upper packer and the second lower packer and configured to inflate the first upper packer and the first lower packer and the second upper packer and the second lower packer, and the injection line configured to provide leachate solution through the first dispersion screen and the second dispersion screen; wherein the dual packer assembly is configured to deliver the leachate solution through the first dispersion screen to a first interval of the borehole bounded by the first upper packer and the first lower packer and through the second dispersion screen to a second interval of the borehole, the second interval lower than the first interval within the borehole and bounded by the second upper packer and the second lower packer.
6. The dual packer injection leaching system of claim 5, further comprising a crane hook configured to support the dual packer assembly during installation of the dual packer assembly inside the borehole.
7. The dual packer injection leaching system of claim 5, further comprising a support structure coupled to a chain hoist, the chain hoist coupled to the dual packer assembly and configured to support the dual packer assembly.
8. The dual packer injection leaching system of claim 5, wherein the borehole extends into the leach pile at an incline.
9. The dual packer injection leaching system of claim 5, further comprising a wire rope coiled around a wire rope reel drum, the wire rope further coupled to the dual packer assembly.
10. The dual packer injection leaching system of claim 9, further comprising the wire rope, the injection line, and the pneumatic line coupled together with plastic ties placed at intervals of 3 meters or less.
11. The dual packer injection leaching system of claim 5, further comprising a leachate solution sprinkler system coupled to the injection line and configured to supply leachate solution to the injection line.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Implementations will hereinafter be described in conjunction with the appended drawings, where like designations denote like elements, and:
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15) Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of implementations.
DETAILED DESCRIPTION
(16) This disclosure, its aspects and implementations, are not limited to the specific material types, components, methods, or other examples disclosed herein. Many additional material types, components, methods, and procedures known in the art are contemplated for use with particular implementations from this disclosure. Accordingly, for example, although particular implementations are disclosed, such implementations and implementing components may comprise any components, models, types, materials, versions, quantities, and/or the like as is known in the art for such systems and implementing components, consistent with the intended operation.
(17) The word exemplary, example, or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as exemplary or as an example is not necessarily to be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not meant to limit or restrict the disclosed subject matter or relevant portions of this disclosure in any manner. It is to be appreciated that a myriad of additional or alternate examples of varying scope could have been presented, but have been omitted for purposes of brevity.
(18) While this disclosure includes a number of implementations that are described in many different forms, there is shown in the drawings and will herein be described in detail particular implementations with the understanding that the present disclosure is to be considered as an exemplification of the principles of the disclosed methods and systems, and is not intended to limit the broad aspect of the disclosed concepts to the implementations illustrated.
(19) In the following description, reference is made to the accompanying drawings which form a part hereof, and which show by way of illustration possible implementations. It is to be understood that other implementations may be utilized, and structural, as well as procedural, changes may be made without departing from the scope of this document. As a matter of convenience, various components will be described using exemplary materials, sizes, shapes, dimensions, and the like. However, this document is not limited to the stated examples and other configurations are possible and within the teachings of the present disclosure. As will become apparent, changes may be made in the function and/or arrangement of any of the elements described in the disclosed exemplary implementations without departing from the spirit and scope of this disclosure.
(20) The present disclosure relates to an injection leaching system 100 configured to provide access to the blinded off portions of the leach pile 102. A borehole 104 is drilled into the leach pile 102. The borehole 104 may extend into the leach pile 102 vertically, horizontally, or at an incline. In some embodiments, a well casing 106 is installed within the borehole 104. The well casing 106 may have a solid wall along a majority of the length of the well casing 106, with intervals 108 of a screened wall. The depth of the screened intervals 108 may be selected based on the specific characteristics of the borehole 104, such as the composition of the leach pile 102, the location of the desired mineral within the leach pile 102, and the location of the barrier blinding off the leach pile 102, among other characteristics. A desired flow path for leaching activity may be selected, and the depth of the screened intervals 108 may be selected based on this desired flow path. The screened intervals 108 may be between 10 and 20 feet in length. The screened intervals 108 may be located at regular intervals, or may have different distances between them. For example, in some embodiments, there may be a fifty-foot solid section of well casing between each screened interval 108. In other embodiments, the solid section of well casing may have a length between 70 and 75 feet, 40 and 60 feet, or any other range. In a specific embodiment, the well casing 106 may have several hundred feet of solid casing, then a ten-foot screened interval 108, a fifty-foot section of solid casing, another ten-foot screened interval 108, a sixty-foot section of solid casing, and a last ten-foot screened interval 108.
(21) Both the location of the borehole 104 and the depth and location of the screened intervals 108 may be determined based on an investigation of the composition of the leach pile 102. Samples may be taken of the leach pile 102, and then the injection leaching system 100 may be designed to access the portions of the leach pile 102 where mineral rich strata are now known to exist, or to access the portions of the leach pile 102 most blinded off by the hydraulic barrier. Thus, the four general steps of gaining access to the blinded off desired minerals are determining the composition of the leach pile 102, designing the injection leaching system 100, installing the injection leaching system 100, and operating the injection leaching system 100. In addition to determining the location of mineral rich areas, the investigation also aids in determining the required pressures to drive the leachate solution into the surrounding leach pile 102. The investigation may also reveal physical characteristics of the leach pile 102, such as hydraulic conductivities, grain-size distribution, clay content, and chemical signatures, which help in the design of the injection leaching system 100.
(22)
(23) The screen material used for the high dispersion screen 116 is a high dispersion material. A schedule 40 or schedule 80 polyvinyl chloride (PVC) recovery well screen is typical for other boreholes, but is not sufficient for the present application because of the associated head loss that occurs when pumping the leachate solution or water through the high dispersion screen 116. Thus, the high dispersion screen 116 may be a stainless steel high dispersion screen. As non-limiting examples, the high dispersion screen 116 may be a Roscoe stainless steel high dispersion water well screen or a Johnson stainless steel high dispersion water well screen.
(24) In some embodiments, the dual packer assembly 110 may further comprise a second upper packer 112, a second lower packer 114, and a second high dispersion screen 116 disposed between the second upper packer 112 and the second lower packer 114. In such embodiments, the pneumatic line 118 is coupled to the second upper packer 112 and to the second lower packer 114, and is configured to inflate each of the second upper packer 112 and the second lower packer 114. Additionally, the dual packer assembly 110 is configured to deliver the leachate solution through the second high dispersion screen 116 to a second interval 108 of the borehole 104. The second interval 108 may be lower than the first interval 108 within the borehole 104, and may be bounded by the second upper packer 112 and the second lower packer 114. Some embodiments include additional sets of an upper packer 112, a lower packer 114, and a high dispersion screen 116 to allow the dual packer assembly 110 to provide leachate solution to multiple screened intervals 108 simultaneously.
(25) Moving to
(26) Moving to
(27) As shown in
(28) Once the dual packer assembly 110 has been lowered into the borehole 104 just past the surface, the mobile deployment system 140 is moved closer to the borehole 104 to align the bend pulley 146 with the borehole 104, as shown in
(29) The support structure 124, such as a tripod as shown in
(30) A method for using the injection leaching system 100 in a leach pile may comprise inserting the dual packer assembly 110 into the borehole 104 in the leach pile 102, providing a hose reel drum 144 with a pneumatic line 118 and an injection line 120, inflating the upper packer 112 and the lower packer 114 through the pneumatic line 118 to fix a position of the upper packer 112 and the lower packer 114 within the borehole 104, and delivering a flow of leachate solution through the injection line 120 and the high dispersion screen 116 of the dual packer assembly 110 to an interval 108 of the borehole 104 bounded by the upper packer 112 and the lower packer 114. As described above, the borehole 104 penetrates the barrier blinding off the leach pile 102, and thus the blinded off area can be supplied with leachate solution for leaching activity. As leachate solution is delivered to the interval 108, the leachate solution flows into the surrounding leach pile 102. Because horizontal conductivity of fluid is greater than vertical conductivity, this leach activity is able to penetrate horizontally into the leach pile before filtering downward to be collected. Generally, the leachate solution used is a sulfuric acid, which may be diluted. However, other fluids may be used for leaching. In addition, the leachate solution may be replaced with water, and the method may include rinsing the interval 108 with water. The method may also include pulsing the pressure of the leachate solution to induce flow into the leach pile 102. The inflated upper packer 112 and lower packer 114 allow the pressure to increase over the interval 108. In addition, the method may include pumping air through the injection line 120 and pulsing the air pressure. An air compressor, a windmill, or some other air pump could be used to pump the air. Bacteria within the leach pile 102 increases the leach rate of the leaching activity. Thus, it is beneficial to provide air to the leach pile, to help bacteria flourish.
(31) Inserting the dual packer assembly 110 into the borehole 104 may comprise lifting the dual packer assembly 110 with a crane hook 138. The method may also comprise suspending the dual packer assembly 110 from the chain hoist 126 coupled to the support structure 124, and may comprise coupling the injection line 120 to the leachate solution sprinkler system 136 and supplying leachate solution to the injection line 120 with the leachate solution sprinkler system 136. The method may further comprise delivering the flow of leachate solution through the injection line 120 to a second interval 108 of the borehole 104 lower than the first interval 108 of the borehole 104.
(32) Another method for using the injection leaching system 100 in a leach pile 102 may include the following steps, as illustrated by
(33) In embodiments where a new screened interval is selected, the mobile deployment system 140 may be placed adjacent the borehole 104 again, and the mobile deployment system 140 may be used to adjust the depth of the dual packer assembly 110 to the new desired screened interval 108. The dual packer assembly 110 may then be installed again as explained above, where the weight of the dual packer assembly 110 is transferred again to the support structure 124, the packers 112, 114 are inflated, and the leachate solution is injected to the desired screened interval 108.
(34) It will be understood that implementations of an injection leaching system are not limited to the specific assemblies, devices and components disclosed in this document, as virtually any assemblies, devices and components consistent with the intended operation of an injection leaching system may be used. Accordingly, for example, although particular injection leaching systems, and other assemblies, devices and components are disclosed, such may include any shape, size, style, type, model, version, class, measurement, concentration, material, weight, quantity, and/or the like consistent with the intended operation of injection leaching systems. Implementations are not limited to uses of any specific assemblies, devices and components; provided that the assemblies, devices and components selected are consistent with the intended operation of an injection leaching system.
(35) Accordingly, the components defining any injection leaching system may be formed of any of many different types of materials or combinations thereof that can readily be formed into shaped objects provided that the materials selected are consistent with the intended operation of an injection leaching system. For example, the components may be formed of: polymers such as thermoplastics (such as ABS, Fluoropolymers, Polyacetal, Polyamide; Polycarbonate, Polyethylene, Polysulfone, and/or the like), thermosets (such as Epoxy, Phenolic Resin, Polyimide, Polyurethane, Silicone, and/or the like), any combination thereof, and/or other like materials; glasses (such as quartz glass), carbon-fiber, aramid-fiber, any combination thereof, and/or other like materials; composites and/or other like materials; metals, such as zinc, magnesium, titanium, copper, lead, iron, steel, carbon steel, alloy steel, tool steel, stainless steel, brass, nickel, tin, antimony, pure aluminum, 1100 aluminum, aluminum alloy, any combination thereof, and/or other like materials; alloys, such as aluminum alloy, titanium alloy, magnesium alloy, copper alloy, any combination thereof, and/or other like materials; any other suitable material; and/or any combination of the foregoing thereof. In instances where a part, component, feature, or element is governed by a standard, rule, code, or other requirement, the part may be made in accordance with, and to comply under such standard, rule, code, or other requirement.
(36) Various injection leaching systems may be manufactured using conventional procedures as added to and improved upon through the procedures described here. Some components defining an injection leaching system may be manufactured simultaneously and integrally joined with one another, while other components may be purchased pre-manufactured or manufactured separately and then assembled with the integral components. Various implementations may be manufactured using conventional procedures as added to and improved upon through the procedures described here.
(37) Accordingly, manufacture of these components separately or simultaneously may involve extrusion, pultrusion, vacuum forming, injection molding, blow molding, resin transfer molding, casting, forging, cold rolling, milling, drilling, reaming, turning, grinding, stamping, cutting, bending, welding, soldering, hardening, riveting, punching, plating, and/or the like. If any of the components are manufactured separately, they may then be coupled with one another in any manner, such as with adhesive, a weld, a fastener (e.g. a bolt, a nut, a screw, a nail, a rivet, a pin, and/or the like), wiring, any combination thereof, and/or the like for example, depending on, among other considerations, the particular material forming the components.
(38) It will be understood that methods for manufacturing or assembling injection leaching systems are not limited to the specific order of steps as disclosed in this document. Any steps or sequence of steps of the assembly of an injection leaching system indicated herein are given as examples of possible steps or sequence of steps and not as limitations, since various assembly processes and sequences of steps may be used to assemble injection leaching systems.
(39) The implementations of an injection leaching system described are by way of example or explanation and not by way of limitation. Rather, any description relating to the foregoing is for the exemplary purposes of this disclosure, and implementations may also be used with similar results for a variety of other applications employing an injection leaching system.