长距离浆体管道输送的技术经济（拉迈西 L.甘地）.ppt

FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007第一届中国昆明国际学术研讨和技术交流会,TECHNICALECONOMICASPECTSOFLONGDISTANCESLURRYPIPELINES长距离浆体管道输送的技术经济,PresentedbyRameshL.GandhiPipelineSystemsIncorporated管道系统工程公司,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,INTRODUCTION介绍,PSIishappytohavetheopportunitytopresentthemainaspectsoflongdistanceslurrytransportationatthisconference.PSI非常高兴借这个机会对长距离浆体输送的主要方面作一个介绍.PSIhas22yearsofworldwideexperienceinslurrypipelinesystemdesign.Longdistanceslurrypipelinesystems,Tailingsandthickenedtailings,andoffshoredisposalsystemsPSI在全球浆体管道系统长距离浆体管道系统,尾矿和浓缩尾矿,以及近海尾矿填埋系统设计方面已有22年的经验.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,KeyObjectives主要内容,Discussthehistoricaldevelopmentofthetechnologyandcurrentstatus讨论技术的历史发展和现状Designaspectsofslurrypipelines浆体管道的设计Materialandequipmentselection材料和设备选取Pipelineconstructionissues管道施工,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,KeyObjectives主要内容,Advantagesandlimitationscomparedtoothermodesoftransport与其它输送方法相比存在的优势和缺陷Applicationinremoteminedevelopment在偏远矿山发展中的应用Recentexamplesofslurrypipelines近期修建的浆体管道Futureapplications应用前景,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,History-历史,Firstreportedapplicationingoldrush-California1850.第一次有记载的是在1850年在加利福尼亚淘金热中的应用.FirstlicenseinU.S.A.in1889.第一次获许可是在1889年于美国.FirstacademicstudybyNoraBlatchin1906.第一次学术研究是在1906年由NoraBlatch开展的.PipelineindustrialapplicationinEnglandin1914.1914年在英格兰开始管道的工业应用.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,History-历史,Majortechnicalandacademicdevelopmentduring50’sthrough70’s.50年代至70年代期间主要的技术和学术发展.SlurrytransportationcodesANSI/ASMEB31.11in1986firstedition.浆体输送规范ANSI/ASMEB31.11,1986年第一版.Consolidationcoalslurrypipeline1955固结煤浆管道1955年SavageRiverIronConcentratePipelineinTasmania1967塔斯马尼亚萨维季河铁精矿浆管道1967,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,History历史,BlackMesaCoalslurryPipelineinUSA1970美国黑梅萨煤浆管道1970年Copperconcentrateandlimestoneslurrypipelines1970s铜精矿和石灰石矿浆管道70年代LargestIronconcentratepipelineSamarcoinBrazil1982大型铁精矿输送管道,1982年于巴西Samarco.AlargenumberofmineralconcentrateandtailingsslurrypipelinesareinoperationthroughouttheworldincludingrecentlycommissionedironconcentratepipelineinthePeoplesRepublicofChina2007andafirstofit’skindBauxiteoreslurrypipelineinBrazil2007全球有许许多多精矿管道和尾矿管道在运行,包括近期2007年在中国投入试车运行的铁精矿管道和在巴西投入使用的全球第一条铝土矿浆管道.Anumberofnewprojectsareinvariousstagesofdevelopment有许多新的项目正处在建设的不同阶段.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,DesignAspects设计方面,HydraulicProcessdesign-水力工艺设计MechanicalDesign-机械设计Equipmentandmaterialselection-设备和材料选取Pipelineconstruction-管道施工OperationandControl-操作和控制,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,HydraulicDesign-水力设计,SlurryFlowBehavior-浆体流特点PipelineThroughputmaximum,minimumandnominal管道输送能力最大,最小和名义能力PropertiesofSolidsandcarrierfluid-固体和输送介质特性Pipelinerouteselection-管道线路的选取Corrosionerosionandoperability-腐蚀磨损及可操作性Pumpandpipematerialrequirements-泵和管道材料要求Slackflowcontrolforpressurizedpipes-压力管道的加速流控制Openchannelflow-明渠流,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,SlurryFlowBehavior浆体流状态,Theslurryflowbehaviordependsuponthesizeandspecificgravityofsolids-浆体流特点取决于固体颗粒比重及尺寸Largeparticlestendtosettledownandabeddepositonpipebottom-大颗粒容易沉降并在管底形成一个沉降床Ifslurrycontainsonlylargeparticles,thesolidswillbouncealongthebottomofthepipewithveryfewparticlesnearthetopofthepipe.Thistypeofflowiscalledstratifiedflowandisencounteredintransportingcoarsesandandgravel-如果浆体中只含大颗粒,固体将沿管底反跳,而管顶附近的颗粒极少.这种浆体流称为层流,在输送粗砂和砾石时会遇到.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,SlurryFlowBehavior-浆体流状态,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,SlurryFlowBehavior浆体流状态,Iftheslurrycontainsveryfineparticlessmallerthan10micronoritisflocculated,theparticlesdonotsettledownunderstaticcondition.Thistypeofslurrygivesrisetohomogeneousflowbehaviorwithuniconcentrationgradient.Kaolinclayanddigestedsewagesludgearetypicalexamplesofsuchslurries-如果浆体颗粒非常细小于10微米或者呈絮凝状,那么在静止状态下颗粒不会沉降.这种浆体将呈均质流特征和一致的浓度梯度.高岭土和消化污泥是这种浆体的典型例子.Iftheslurrycontainsparticleslargerthan10micronsthentheslurrywilltendtosettleinstaticcondition-如果浆体颗粒大于10微米,则在静止状态下容易沉降.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,SlurryFlowProperties-浆体流特性,Tokeeptheparticlesinsuspension,turbulentflowwillbeneeded.Velocityatwhichparticlestendtoabedofsolidsinthepipeiscalleddepositionvelocity.Pipelinesaredesignedtoflowatvelocitiesabovedepositionvelocity-为了保持颗粒悬浮,需要形成紊流.颗粒容易在管道中形成沉降床的速度称为沉降速度.管道流速设计高于沉降速度.Iftheslurrycontainsarangeofparticlesizessuchthatthefinercomponentlessthan10microngivesrisetonon-Newtonianbehavior,thenthevelocityatwhichturbulentflowoccurscanbehighercomparedtothatforcoarseslurry-浆体颗粒尺寸范围中较细颗粒小于10微米增加非牛顿体的特性,那么产生紊流的速度相比于粗颗粒浆体会更高.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,SlurryFlowBehavior-浆体流特征,Tokeepthelargerparticlesinsuspension,turbulentflowwillbeneeded.Velocityatwhichflowchangesfromlaminartoturbulentiscalledtransitionvelocity.Withnon-NewtonianslurrytheReynoldsnumberatwhichflowchangesfromlaminartoturbulentcanbemuchhighercomparedtoNewtonianslurry-为保持大颗粒悬浮,需要形成紊流.流体从层流转为紊流的速度称为过渡流速.对于非牛顿体浆体流,流体从层流转为紊流的雷诺数会大大高于牛顿体浆体流.NewtonianTheshearstressisproportionaltoshearrateandtheconstantofproportionalityiscalledviscosityoffluid-牛顿体剪切应力与剪切率成正比,该比例系数称为流体粘度.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,SlurryFlowBehavior-浆体流特性,Non-NewtonianTheshearstressisnotproportionaltoshearstress.Pseudoplastic,Binghamplastic,Herschel-BulkleyandPasticmodelshavebeenusedtodefinenon-Newtonianflowbehavior-非牛顿体剪应力与剪切率不成正比.Pseudo塑性粘度,Bingham塑性粘度,Herschel-Bulkley和塑性粘度模型都已用于定义非牛顿体流体特性.Wewillnotgointomathematicaldetailsofvariousmodels.在这里我们将不对各个详细的数学模型作探讨.Thepressuredropinagivensizepipeincreaseswithanincreaseinvelocityofflow-对于给定尺寸的管道,随着流速的增加,压降也会增加.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,SlurryFlowBehavior-浆体流特性,Itisthereforenecessarytokeepthedesignvelocityaslowaspossible.However,itshouldexceedboththetransitionvelocityaswellasthedepositionvelocity-因此有必要保持尽可能低的设计流速.但是,该速度应大于过渡流速及沉降流速.Asthevelocityofflowincreases,theerosioninthepipeincreases-当流速增加时,管道内部的磨损也会增加.Mostslurriesrequiredewateringatendofthepipeline.Thedewateringbecomeseasierwithcoarsesizeparticles.多数矿浆需要在终端进行脱水.对于粗颗粒浆体脱水更容易一些.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,SlurryFlowBehavior-浆体流特性,Itisthereforenecessarytokeeptheparticlesizesmallenoughtopreventerosionandalsolargeenoughtokeeplowdewateringcost-因此有必要保持足够小的颗粒以防止磨损,同时也要保持颗粒足够大以降低脱水成本.Mostmineralconcentrateisproducedinslurryasapartofbeneficiationprocess-大多数精矿都是以浆体的形式在选矿厂生产出来的.Thesizeconsistofconcentrateslurryisgenerallysuitableforlongdistancetransport-精矿浆的颗粒粒度分布通常适合于长距离管道输送.Attimesadditionalgrindingisrequiredtokeepthesolidsfineenoughforlongdistancetransport-有时需要对精矿进行额外的研磨,以保证固体颗粒足够细适合长距离输送.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,HydraulicDesign-水力设计,Characteristicsofsolids-固体颗粒特性,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,HydraulicDesign水力设计,SizeConsistofSolids固体粒度分布,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,HydraulicDesign水力设计,SlurryConcentration浆体浓度,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,HydraulicDesign水力设计,CarrierFluid-运载流体Waterusedineralbeneficiationisusedascarrierfluid用选矿的水作为输送介质Largeamountofwaterisneeded-需要大量的水Watersupplymaybeexpensive-供水可能很昂贵Onlyalimitedamountofwaterisusedatthepipelineterminal-在管道终端只用限量的水Remainingwatermustbetreatedanddisposedoff-剩余的水必须进行处理然后外排RecycleSystemcanbeconsideredforshortpipelines-短距离管道可考虑建再循环系统Alternativetransportationmediummaybeconsidered可考虑采用其它输送介质,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,HydraulicDesign-水力设计,Slurryflowpropertiesforlongdistancepipelines-长距离管道的浆体流特性Plasticviscosityintherangeof5-30mPasissuitable塑性粘度在530毫帕.秒范围内为合适.BinghamPlasticYieldstressshouldbelessthan10Pa宾汉塑性屈服应力应小于10Pa.Slurryflowpropertiesofbauxiteandnickeloremaychangewithtimeofshearduetoattritionofparticlesaswellasliberationofclay-铝土矿和镍矿浆体流的特征可能会由于颗粒的磨损和粘土的释放而随剪切时间发生改变.Theeffectofpipelineshearrateandthetransittimeinpipelineshouldbeuatedfordesign-设计时应对管道剪切率效应和输送时间进行评估.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,HydraulicDesign水力设计,VelocityofFlow-流速Sufficientlyhightoachieveturbulentflow-应足够高以形成紊流Shouldexceedvelocitybelowwhichsolidstendtobeddeposit-应大于容易导致固体沉降的流速.Highervelocitygiverisetohigherfrictionloss-高流速将导致高摩阻损失Forlongdistancetransport10kmormorevelocityintherangeof1.5to2.0m/sisfoundeconomical-对于长距离输送管道10公里或更长,流速处于1.5至2.0米/秒范围内是经济的.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,HydraulicDesign水力设计,Operability可操作性Stoppageofslurryflowgivesrisetosettlingofsolidsthatabedonpipebottom-浆体流的中断将导致固体在管底沉降形成沉降床.Mostlongdistancepipelinesencounterhillsandvalleys-大多数长距离管道都会经过山丘和山谷.Thesolidstendtoaccumulatenearthleysduringshutdownofthepipeline-在管道停止运行期间,固体容易堆积在山谷区.Particlesizeandslurryconcentrationareselectedtopreventdifficultiesduringrestartafterapipelineshutdownwithslurry-粒度和矿浆浓度的选取应能防止出现带浆停车再启动的障碍.Flocculatedsolidstendtorestarteasilycomparedtodispersedsolids-相比于分散固体,絮凝固体更容易再启动.Pipelineslopesarelimitedtoreducetheamountofsolidsaccumulatinginthleysandconsolidationofdepositsduetoincreasedweightofsolids-限制管道的坡度以减少固体堆积在山谷区的量和避免由于沉降物重量的增加而导致的固结现象.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,HydraulicDesign水力设计,PipelineRouteLengthandProfile-管道线路长度和剖面Straightlinerouteisshortest-直线线路是最短的.Deviationfromstraightlinearerequiredbasedon-在以下情形下可以偏离直线线路EaseofConstructionavoidsteephillsorravines,rockyorenvironmentallysensitiveareas-为了施工便利避免陡坡或沟壑,多岩或敏感环境区域.Landuse–征地Accessrights-通行权FutureMiningPlans-将来的开采方案,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,PipelineRouteSelection-管道线路选取,Whenselectingaroute,preparepipelineelevationprofile.Selectaroutethatreducestheelevationofhighpointsdownstreamofthestartingpointelevation-选取线路时,准备好管道标高断面图.选取的线路应降低起点标高下游的高点标高.Thepipelineslopeislimitedto15toavoidrestartproblems-管道坡度限制在15以避免带将停车再启动的问题.Iftherearefewhighpointsthatsignificantlyincreasepumpingpressurethenconsiderareroutealongthehillsorusetunnelsiffoundeconomical-如果有极少数高点明显提高泵压的话,如果经济可行,可考虑沿山坡重新选线或采用隧洞.Avoidunstableareas,hardrockandmajorriversandroadsifpossible-避开不稳区域,坚硬岩石和大型河流及公路.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,PipelineRouteSelection管道线路选取,Considerationshouldbegiventodangersofavalancheandunstablegroundconditions-应考虑到雪崩和不稳的地面条件的危险.Avoidurbanareasandmarshlandsifpossible-如果有可能,避开市区和沼泽地.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,HydraulicDesign-水力设计,Corrosionerosion-腐蚀/磨损Corrosivenessofwaterisincreasedbythepresenceofsolids-由于固体的存在而增加了水的腐蚀性.Theparticlesizeandslurryconcentrationarecontrolledforlongdistancetransportinordertopreventabrasionofpipematerial-需要控制粒度和浆体浓度以防止对管材的磨损.Internalliningsmaybeneedediftheslurryishighlycorrosiveorabrasive-如果浆体是高腐蚀性或高磨损性的,则可能需要给管道加内衬.Costofcorrosion/abrasioncontrolshouldbecomparedwiththecostofliningforpipematerialselection-选取管道材料时,应该作腐蚀/磨损费用与内衬费用的比较.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,HydraulicDesign水力设计,PumpandpipematerialRequirements-泵和管道材料要求Lengthofpipeandchangeinelevationdeterminepumpingrequirements-管道长度和标高的变化决定对泵的要求Morethanonepumpstationmaybeneededwithlongpipelineorwhenpumpingtohigherelevation-对于长距离管道或者泵送标高较高时可能需要不止一个泵站.Thepipewallthicknessincreaseswhenpumpingpressureisincreased-当泵压增加时,管壁厚度也增加.Numberofpumpstationsselectedisbasedoneconomicanalysisofpumpstationandpipematerialcosts-泵站数量的确定根据泵站和管材费用分析作出.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,Corrosion腐蚀,Corrosionproductsareintheofhydratedferricoxide,magnetiteorhematite-腐蚀产品的形式有水合氧化铁,磁铁矿或赤铁矿.Theseabarrieragainstdiffusionofoxygentothecathodicregionandthusreducecorrosionrate-这些物质形成一层保护层防止氧气扩散到阴极区,从而降低腐蚀率.Presenceofchloridesandsulfidesdestroythisbarrier氯化物和硫化物的存在会破坏这个保护层Abrasionduetosolidscouldalsoremovethebarrier固体的磨损同样也会破坏这个保护层.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,Corrosion腐蚀,Pittingsometimesoccursunderthelayerofoxidesthatserveasabarriertocorrosion-有时在起腐蚀保护的氧化物层下面会发生坑蚀现象.Nonuniityofthecorrosionlayercansetupcorrosioninverysmallareaswherethemetallossbecomeshighandgivesrisetopitsthatarequitedeep-腐蚀保护层的不均匀性可能会在小范围内导致出现腐蚀,在这些范围内金属的损失会增加而导致出现较深的腐蚀坑.Pittingisinducedbyhalogens,SCN-,SO4,Fe3,Cu3,Hg2anddissolvedoxygen-坑蚀是由于卤素,SCN-,SO4,Fe3,Cu3,Hg2的存在而导致出现的.SusceptibilityofsteeltopittingincreaseswithhigherpHPH值越高,越容易出现坑蚀.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,Corrosion腐蚀,Removalofdissolvedoxygenreducescorrosionrate.Catalyzedsodiumsulfitehasbeenusedforcorrosioncontrol-去除溶解氧可降低腐蚀率.催化亚硫酸钠已被用于腐蚀控制.UseoflimetoincreaseslurrypHhasbeenfoundtoreducecorrosionrateofmineralconcentrates-已发现利用石灰提高矿浆PH值可降低精矿的腐蚀率.Polyphosphates,boratesandsilicatescaninhibitcorrosionbyingprotectivefilmsofironcompoundsincathodicareas-聚磷酸盐,硼酸盐和硅酸盐可通过在阴极区形成一个铁化合物保护膜而起到抑制腐蚀的作用.Zinchasalsobeenusedincombinationwithpoly-phospahatestogivecorrosionprotection-另外结合使用锌和聚磷酸盐也能起到防腐蚀的作用.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,Corrosion腐蚀,Corrosioncanalsobeeliminatedusinginternalpipelining-采用内衬也能消除腐蚀.HDPElinershavebeenusedinanumberofcopperslurrypipelinesinUSA,Chile,PeruandArgentina-HDPE内衬已经大量地用在美国,智利,秘鲁和阿根廷的铜矿浆管道中.Aneconomicanalysisisneededtodeterminethecosteffectivenessoflinerscomparedtochemicaltreatmentanduseofadditionalpipesteelforcorrosionallowance-在与化学处理和使用额外的用作腐蚀余量的钢管两种方法比较之后,需要进行经济分析来确定采用内衬的成本效益.,FirstKunmingChinaInternationalScienceSeminarandTechnicalExchangeMeeting,Sept11-13,2007,Erosion磨损,Erosionorabrasionofapipewallresultsfromthedynamicactionofmovingparticles-管道的磨损是由于运动颗粒的动态作用而导致的.Deationwear–causedbyimpact-变形磨损-由于冲击而导致的Cuttingwearcausedbyslidingofparticles-切割磨损是由于颗粒的滑动而导致的.Solidsmustbeharderthanpipetoabradeit-固体一定比管子硬才会产生磨损.Silicahasahardnessof800kg/mm2ascomparedtosteelhardnessthatrangefrom200to800kg/mm2-硅石的硬度为800kg/mm2,而钢的硬度范围在200至800kg/mm2.Useoffinersizeconsistandvelocitiesbelow2.5to3m/sgenerallyeliminateserosivewear-采用较细的粒度分布和流速低于2.5-3m/s通常可以消除侵蚀磨损