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Africa Iron 2014 Conference, June 2014, Slide 1
www.PatersonCooke.com
Slurry pipelines - A viable option for West African iron projectsDr Angus Paterson, Paterson & Cooke, Cape Town
Africa Iron 2014
Africa Iron 2014 Conference, June 2014, Slide 2
Introduction
Africa is endowed with world class mineral resources
Many of these resources are located in regions where road and rail
access is limited, for example Marampa (Sierra Leone), Zanaga
(Congo)
The lack of infrastructure often inhibits the development of an ore body
that requires a suitable export corridor for large volumes of mineral
concentrate
Chile and Brazil provide good examples of where slurry pipelines have
enabled the development of resources
Africa Iron 2014 Conference, June 2014, Slide 3
Outline of presentation
Options for bulk transport
A brief background to long distance concentrate slurry pipelines
Examples of long distance pipelines transporting a range of
commodities/concentrates
The requirements to produce a suitable product for pumping
Advantages and disadvantages of concentrate slurry pipelines
Africa Iron 2014 Conference, June 2014, Slide 4
Short haul trucking
• Within mine fence, < 20 km
Long haul trucking
• Beyond mine fence, up to 75 km
Overland conveyor
• Single flight up to 50 km or more
• 10% grade, horizontal radius limits, dusting
Ore trains / rail
• Sishen to Saldahna 800 km = unlimited distance
• 1% maximum grade when loaded = longer routes, crossings costly
• Continuous power supply along route
Slurry Pipelines – fine particle transport
• Viable over long distances
• Water, particle preparation (grinding and drying) requirements
• Steep terrain limits (10% to 15% grade)
Ore concentrate transport system options
Haul roads, grade limits, high
running costs, flexible, can be
contracted
Africa Iron 2014 Conference, June 2014, Slide 5
Slurry pipelines - historical background
First major long distance ore pipeline system was Consolidation Coal
(172 km, 1.3 Mt/a, 1957)
• Railways reduced tariffs and system was mothballed but kept in care &
maintenance
President Kennedy promoted the idea of long distance coal pipelines in
1962 to help ailing coal industry in USA
Africa Iron 2014 Conference, June 2014, Slide 6
Pipeline politics
Africa Iron 2014 Conference, June 2014, Slide 7
Black Mesa coal slurry pipeline
1970: Black Mesa coal pipeline was commissioned:
• 440 km long
• 450 mm diameter pipeline
• Transported 4.8 Mt/a of coal
The Peabody Coal Mine used water from the underground Navajo
Aquifer (only plant that used groundwater in such a way)
Coal slurry pumped to Mohave Power Station in Nevado that supplied
power to California and Nevada
Operated until 2005
?
Africa Iron 2014 Conference, June 2014, Slide 8
On the success of the Black Mesa pipeline project:
• Pipelines proved to be a cost effective alternative to conventional coal transport
• 1973 - Energy Transportation Systems Inc (ETSI) project started
• Aim to develop, build and operate ± 2250 km of coal pipelines transporting 30
MTA coal, linking Wyoming, Colorado, Kansas, Oklahoma, and Arkansas
Africa Iron 2014 Conference, June 2014, Slide 9
But then . . .
Late 1970’s - US railways barred slurry pipelines from crossing their servitudes,
effectively blocking long distance pipelines in the USA
History has a short memory
Effectively ended developments in long distance slurry pipeline technology
in USA
However, elsewhere projects continued . . .
Africa Iron 2014 Conference, June 2014, Slide 10
Iron ore pipelines: Savage River
Savage River Mine situated in north west Tasmania in mountainous terrain
Pipeline commissioned in 1967
85 km from mine to pelletisation plant & port terminal
Unlined 250 mm pipeline, 13.5 – 6.3 mm thick
2.3 Mt/a
65%m magnetite
Max particle size 149 µm (d80 43 µm)
Single pump station with 4 +1 triplex plunger pumps, 11.7 MPa
Design life was 20 years (35 years operation to date)
Lime and sodium sulphate oxygen scavenger added
88 % availability reported
10% slope
Magnetisation of ore had up to 10% effect on pumping pressure
Africa Iron 2014 Conference, June 2014, Slide 11
Iron ore pipelines: Savage River
Savage River Pipeline Bridge:129 m high and 439 m spanhttp://www.highestbridges.com/wiki/index.php?title=Savage_River_Pipeline_Bridge
Africa Iron 2014 Conference, June 2014, Slide 12
Iron ore pipelines: Samarco
Mine situated in central Brazil near Belo Horizonte
Commissioned in 1977
396 km from mine to coast
Pipelines:
• 12 to 15 Mt/a in original 500 mm diameter pipeline
• 2nd pipeline commissioned in 2008
• 3rd pipeline (20 Mt/a) 550 mm diameter due for commissioning in 2014
Four pelletising plants required
70%m haematite (itabiritic ore)
Max particle size 75 µm (d90 43 µm)
Two pump stations with 6 +1 triplex plunger pumps, 15 MPa
Design life was 20 years, however 40 years predicted
Lime added to control corrosion
99 % availability reported
Minimal failures and blockages reported
Africa Iron 2014 Conference, June 2014, Slide 13
Iron ore pipelines: Samarco
Africa Iron 2014 Conference, June 2014, Slide 14
Iron ore pipelines: MMX Iron Ore, Brazil
Anglo American Iron Ore - 529 km iron concentrate pipeline
From mine site in Minas Gerais to terminal at the coast
Combination of 600 and 650 mm outside diameter pipeline
Capacity: 27.5 MTA ore
Main pump station at mine site, plus booster pump station
Planned start-up
during 2014
J Harman, Anglo American Iron Ore:
“Global Iron Ore & Steel Forecast”, 11
March 2014, Perth, Australia
http://www.angloamerican.com/~/media/Fil
es/A/Anglo-American-
Plc/media/releases/2014pr/anglo-
american-global-iron-ore-steel-forecast-
2014.pdf
Africa Iron 2014 Conference, June 2014, Slide 15
Iron ore pipelines: African studies
South Africa
• Numerous local studies conducted since the 1970’s
10 MTA from Kathu to Saldanha, Port Nolloth and Vanderbijl Park
10 MTA from Thabazimbi to Richards Bay via Pretoria & Newcastle
Existing large fine ore stockpiles well suited to slurry pipeline transport with
minimum additional processing
Requires pelletizing plant at Saldahna
Kathu
Saldahna
Vanderbijl Park
ThabazimbiPalabora
Richards Bay
Maputo
Port Nolloth
• Palabora to Maputo magnetite
pipeline (1990’s)
Fine stockpile in excess of
240MT
Considered a direct route via
Kruger Park (297 km) and a
southern route (369 km)
Africa Iron 2014 Conference, June 2014, Slide 16
Iron ore pipelines: African studies
Congo:
• Zanaga Project
30 MTA pellet feed
An open pit mining operation and process plant and mine infrastructure
380 km slurry pipeline identified as optimal transportation solution
Data and image obtained from “Zanaga Iron Ore – Pipeline
PFS presentation” link at http://zanagairon.com/project
Port facilities and infrastructure for
dewatering and handling of the iron ore
products for export
• Slurry pipeline offers:
$1 billion capital expenditure savings on
direct costs
Lower execution risk
Africa Iron 2014 Conference, June 2014, Slide 17
Iron ore pipelines: African studies:
Congo:
• Zanaga Project
• Cominco’s Hinda Project
37 km NE of Point Noire
4 MTA phosphate rock
concentrate
Slurry pipeline to port drying
and export facility
• Other possible opportunities?
Africa Iron 2014 Conference, June 2014, Slide 18
Iron ore pipelines: African studies
Sierra Leone
• Marampa
Orebody ± 150 km east of Freetown, limited access and infrastructure
Currently trucking to riverhead, barging downstream and offshore loading is
cumbersome and costly
Several operations could consider a slurry pipeline to terminal at Pepel Port
http://www.fatprophets.com/Member%20Area/Product%20Landing
/Report%20List/Report%20Page/~/media/D8FAC035E257450986
FFADFD717D55D6.ashx
Africa Iron 2014 Conference, June 2014, Slide 19
Solids concentration:
• Typically 50% to 70% solids by
mass
Requirements for Long Distance Slurry Pipelines
Particle size:
• Grind / mill to produce an easily
pumpable material
• Iron ore typically < 100 µm 50%m
1 tonne solids
1 tonne water
67%m
1 tonne solids
0.5 tonne water
Coarse settling
slurries = high
velocities = high
power
consumption and
wear rates
High concentration
viscous slurries =
high friction losses
= high power
consumption and
short pumping
distances
Africa Iron 2014 Conference, June 2014, Slide 20
Pipeline operating costs driven by power consumption:
• Transport velocity proportional to particle size and concentration
Requirements for Long Distance Slurry Pipelines
Da Hong (1 Mt/a)
Savage River (2.3 Mt/a)
Essar (8 Mt/a)
Jian Shan (2 Mt/a)
Kudremukh (7.5 Mt/a)
Samarco (12 Mt/a)
1.3
1.4
1.5
1.6
1.7
1.8
0 100 200 300 400 500 600M
inim
um
Opera
ting V
elo
city (m
/s)
Pipeline Diameter (mm)
LONG DISTANCE IRON ORE CONCENTRATE PIPELINES• Wear rate proportional to particle
size and velocity
• Pumping pressure proportional to
pumping velocity
• Efficient power consumption
requires a fine grind
The majority of long distance iron ore pipelines mill at mine and pelletize
at terminal
Africa Iron 2014 Conference, June 2014, Slide 21
Slurry Pipeline Transportation Issues
Single use
• Can only be used to transport slurry
• Can transport different slurry types in batches
Water
• Requires a water source
• Treatment at terminal prior to discharge, or return water pipeline
• Product dewatering / filtration required to transportable moisture content
Environmental
• Relatively low environmental impact compared to railway or trucking
• Pipeline is buried so there is no surface impact
• No emission or noise impact
• No spillage or dust losses
Right of Way / Routing
• Need to negotiate a servitude for the transport corridor
• Pipeline generally shorter than road or rail (subject to grade limitation)
Africa Iron 2014 Conference, June 2014, Slide 22
Slurry Pipeline Transportation Issues
Safety
• Minimal safety risk compared with road and rail transport
Sabotage
• Risk of sabotage mitigated by leak detection systems
Weather
• Not affected by adverse weather, continuous operation
Economics
• Power costs dominate, sensitive to electricity and potential fuel price
increases
• Not subjected to possible arbitrary increases in road usage or fuel taxes
Labour
• Requires significantly less labour than other transport methods
Africa Iron 2014 Conference, June 2014, Slide 23
Typical Costs
Operating costs a strong function of
capacity and average particle size:
• Increasing mean particle size from
44 µm to 300 µm increases
operating costs by 10 times
• Unit operating cost per tonne
decreases substantially with
increasing capacity
• Operating cost/tonne generally lower
than rail transport - electricity a
significant variable cost
Capital costs highly dependant on:
• Pipeline size
• Terrain and construction
Trade off studies to determine rail
and pipeline total cost of ownership
44 µm1
10
Re
lati
ve o
pe
rati
ng
cost
Particle size
0.0
3.5
0 50
US$
/to
nn
e
Annual capacity (MTA)
Africa Iron 2014 Conference, June 2014, Slide 24
An established technology – A sample onlyProduct Location Length (km) Diameter (mm) MTA
Coal Black Mesa, Arizona 439 450 4.8
Iron concentrate Samarco, Brazil 395 500 12
Copper Concentrate Alumbrera, Argentina 316 150 0.8
Copper Concentrate Antamina 302 200 - 250 2.2
Coal Belovo-Novosibirsk, USSR 262 525 3
Copper Concentrate Collahuasi, Chile 203 175 1
Phosphate Concentrate OCP, Morocco 187 900 38
Coal Consolidation, Ohio 174 250 1.3
Copper Concentrate Escondida, Chile 167 150 - 175 2.0
Copper Concentrate OK Tedi, PNG 156 150 0.6
Phosphate Conc. Vernal, Utah 153 250 2.9
Phosphate Conc. Simplot, Idaho 138 225 1.9
Copper Concentrate Los Pelambres 120 175 1.1
Ramu Long distance - ore 120 600 3.4
Copper Concentrate Freeport, Indonesia 119 100 - 125 1.3
Iron concentrate Jian Shan, China 105 225 2
Africa Iron 2014 Conference, June 2014, Slide 25
Long distance pipeline technology
Design codes: Since 2013 ANSI B31.4 incorporates ANSI B31.11 for
the design of long distance slurry systems.
Increased high pressure pumping capacity.
• Fewer pumps required, operating at higher pressures and flow rates.
Africa Iron 2014 Conference, June 2014, Slide 26
Long distance pipeline technology
Design codes: Since 2013 ANSI B31.4 incorporates ANSI B31.11 for
the design of long distance slurry systems.
Increased high pressure pumping capacity.
Improved pipe lining technologies.
• HDPE slip lining to combat corrosion and erosion.
Africa Iron 2014 Conference, June 2014, Slide 27
Long distance pipeline technology
Design codes: Since 2013 ANSI B31.4 incorporates ANSI B31.11 for
the design of long distance slurry systems.
Increased high pressure pumping capacity.
Improved pipe lining technologies.
High pressure long service ball valves.
Africa Iron 2014 Conference, June 2014, Slide 28
Long distance pipeline technology
Design codes: Since 2013 ANSI B31.4 incorporates ANSI B31.11 for
the design of long distance slurry systems.
Increased high pressure pumping capacity.
Improved pipe lining technologies.
High pressure long service ball valves.
Choke stations to control slack flow.
Africa Iron 2014 Conference, June 2014, Slide 29
Long distance pipeline technology
Design codes: Since 2013 ANSI B31.4 incorporates ANSI B31.11 for
the design of long distance slurry systems.
Increased high pressure pumping capacity.
Improved pipe lining technologies.
High pressure long service ball valves.
Choke stations to control slack flow.
Multi-species transient analysis.
Control systems.
• Real time pipeline monitoring of
slurry and water batches.
• Leak detection systems.
Africa Iron 2014 Conference, June 2014, Slide 30
Conclusions
Long Distance Slurry Pipelines:
• Long distance slurry pipeline transport is a well established technology.
• Developments in pipeline components result in more efficient systems with
lower maintenance and reduced power costs.
• Require fine grind material and water
• In general:
Require significantly less labour than other transport methods.
Minimal safety risk compared with road and rail transport.
Viability increases with capacity and distance.
Slurry pipelines offer a viable alternative to conventional long distance,
high volume materials handling, especially in areas with limited
infrastructure, difficult access and mountainous terrain.
Evaluate the benefits of slurry transport and the requirements for a
transportable slurry, versus the costs of conventional handling of coarse
ore.