Concept Design of an Ultra-Deepwater Rare Earth Mineral Mining System Interim Design Presentation

17th of March, 2014

Ranald Cartwright Euan Greer

Christopher Blake Russell Torrance

David Fraser Luke Chapman

Presentation Overview
Current Stage of Project Change of Project Focus Overview of Design Configuration Main Design Elements
Riser System Mineral Collection Tool Flow Assurance Processing and Separation Systems Powering and Control Installation and Maintenance

Project Time Plan Next Steps

CHOSEN DESIGN CONFIGURATION

CHOSEN DESIGN CONFIGURATION

Installation

Depth:
Powering Riser System

Processing & Separation

Flow Assurance 4970m

Mineral Collection Tool

5000m

FLOATING HUB

Hopper

Depth:

Hydrocyclones

4970m

Boost Pump

5000m

RISER SYSTEM

RISER STRUCTURE

Initial Configuration
Component Selection

Riser Joint Burst and Loading Criteria specified by ABS

Riser Configuration

5.2ID Riser

Depth:
Integrated Lines Gas/Power/Comms

4970m

Buoyancy Module (Balmoral)

5000m

RISER CONFIGURATION

Depth:

4970m

5000m

MINING AREA ENVIRONMENTAL CONDITIONS

WD (m)

Current Speed (m/s)

5000m Water Depth Hs = 4m and Tp = 9s Unidirectional and Bi-axial Current Profiles

1 500 1000 5000

0.4 0.3 0.3 0.2

MINING AREA ENVIRONMENTAL CONDITIONS

Bi-Axial
OrcaFlex 9.7a Vertical Current Profile 0

Unidirectional
OrcaFlex 9.7a Vertical Current Profile 0

Wave Spectra
OrcaFlex 9.7a Spectral Density for Wave Train 'Hs=4m' 40

-1000

-1000

30

Spectral Density (m^2 / Hz)

-2000

-2000

Z (m)

Z (m)

20

-3000

-3000

10
-4000

-4000

-5000 -0.4

-0.2

0 Speed (m/s)

0.2

0.4

-5000 0 0.2 0.4 Speed (m/s) 0.6 0.8

0 0 0.1 0.2 Frequency (Hz) 0.3 0.4

KEY CHALLENGES

Determining the slip-joint and tensioner orientation Buoyancy Placement to be Sympathetic to Installation

Vessel Loading during Operation

Modelling Challenges

MINERAL COLLECTION TOOL

COLLECTION TOOL CONTROL

Depth:

4970m

5000m

COLLECTION TOOL MOTIONS

Depth:

4970m

5000m

COLLECTION TOOL ANALYSIS

Subsea Electromagnetic Hydrocyclone

Assess forces required to effectively move and control the system

Create a dynamic model of collection tool and assess motion under applied forces:
Control rams Hub Motions Seabed Friction

Impact of Motions
Collection Efficiency and Operability Environmental Considerations

Investigate the method of operation

OPERATION

Depth:

4970m

5000m

FLOW ASSURANCE

LIFT MECHANISM CONFIGURATION

Depth:
Massive Topsides Compressor
[Tengiz Field Khazakstan 10,000 psi]

Bundled Gas Lines x2

Gas Injection at Hub

Centrifugal Boost Pump

[Provides Seabed to Hub Lift]

Flow Assurance 4970m

5000m

TOPSIDES GAS COMPRESSION

Depth:

4970m

5000m

SUBSEA GAS INJECTION

Depth:

4970m

5000m

REQUIRED FLOWRATE Hjulstrm Diagram

FLOW PARAMETERS

Subsea Electromagnetic Hydrocyclone

Gas Lift with Boost Pump
Required Mass : 100 t/hr (dry weight)

Flow at Inlet:
Flow to topsides :

221 t/hr (slurry)

108 t/hr (partially dewatered)

Flow Rate to meet target :

3 m/s

CHALLENGES

Subsea Electromagnetic Hydrocyclone

Key Issues:
Required Mass of lifting gas

Supercritical Liquids
Change in Lifting Properties

Gas Expansion towards surface

CHALLENGES

Subsea Electromagnetic Hydrocyclone

Key Issues:
Required Mass of lifting gas
Air Phase Diagram

Supercritical Liquids
Change in Lifting Properties

Gas Expansion towards surface

PROCESSING & SEPARATION SYSTEM

SYSTEM CONFIGURATION

Separation and Processing

Subsea electromagnetic hydrocyclone

Topside gravity concentrator

Tailings disposal

SYSTEM CONFIGURATION

Subsea Electromagnetic Hydrocyclone

Watson Magnetic Cyclone Design: Magnetic force coupled with centrifugal force Magnetic/Dense particles forced outward REEs collected from underflow Water/Clay to overflow and discharged

SEPARATION ANALYSIS OUTCOMES

Subsea Electromagnetic Hydrocyclone

Hydrocyclone size

Inlet velocity
Required magnetic field strength

Hydrocyclone Equilibrium Conditions

CHALLENGES

Subsea Electromagnetic Hydrocyclone

Assumptions for clay properties Magnetic susceptibility of particles Compatibility with desired flow conditions

TOPSIDE GRAVITY CONCENTRATOR

Knelson Concentrator:

High capacity
Established method

Able to process desired particle size

TOPSIDE GRAVITY CONCENTRATOR

Analysis: Based on subsea separation results Catalogue selection to meet requirements

TAILINGS DISPOSAL

System: Topside and Subsea Disposal Systems In accordance with ISA guidelines

POWERING & CONTROL SYSTEMS

UMBILICAL DESIGN

The umbilical will be a dynamic design, due to the depth of operation. Will be attached to the riser during installation (similar to current drilling operations). Will contain powering and control to the hub components.

UMBILICAL DESIGN

Selection of the power and communication cables currently being chosen with reference to,
IEC 60502-1 (Power cables: 1 kV up to 3 kV) IEC 60502-2 (Power cables: 6 kV up to 30 kV) DNV-RP-F401 (Electrical Power Cables in Subsea Applications)

Internal structural design of the umbilical to be produced, outlining materials and components.

CONTROL SYSTEMS

Buoyancy Modules Automated control of buoyancy modules no longer required. Pipe Control The control of the pipe will be via a hydraulic ram system located in the hub. 3D model of the hydraulic system and its operation. A mathematical model of the control of the hydraulic systems operations (varying control inputs, to find the best operating conditions of the ram).

POWER REQUIREMENTS

Pump and compressor selection yet to be confirmed as operation conditions are required. Once selected, specification of each will be compiled (supplying powering requirements). A total power amount for various operational conditions will then be specified with a suitable generation method chosen. A distribution diagram will be construction outlining power draws and potential losses.

INSTALLATION & MAINTENANCE

INSTALLATION AND MAINTENANCE OF MINERAL RECOVERY SYSTEM

Huisman Dual Multi Purpose Tower (DMPT) Possible hook load of 1,090 tonnes No V-Door limitation due to box shape and not lattice Compatible with specified riser tensioners Moonpool skid cart capable of moving 800 tonne structure such as mineral recovery tool Using Aker CLIP risers it is possible to deploy rapidly

BUOYANCY

Placed on the riser in strategic positions to reduce stresses and to mitigate the weight of the riser Foam buoyancy from Balmoral Offshore can reach depths of 7000 metres

Restricted by the dimensions of moonpool for launching (27m x 11m, Noble Globetrotter)
Plan to create a deck layout encompassing derrick, risers and buoyancy

RESPONSE OF RISER DURING INSTALLATION

Using Orcaflex model to calculate riser response

Continuation of Static Analysis from Riser Section Completed every 20m until riser depth is 200m to accurately measure bending and deflections through splash and wave zone Every 200m thereafter until target depth reached

Analysed to find limiting environmental conditions for installation and retrieval of system
Excess loads assessed during loading and retrieval phase

SYSTEM MAINTENANCE

Investigate components used within project to detail maintenance intervals and procedures Establish the operating window of the system Will allow the maintainability of the system to be assessed and cost estimates provided FMECA undertaken to establish how a failure effects the system as a whole Initial operability found and measures to increase operability window implemented

GOING FORWARD

Properties of buoyancy to be received from Balmoral Offshore Run initial Orcaflex model for first iteration of buoyancy placement Ascertain if parameters such as stress in riser are within acceptable limits in varying environments Compare deck layouts and derive an effective and safe positioning of installation and maintenance equipment Consider procedure if a storm is to hit mining area

Construct FMECA of equipment and investigate effects of preventative measures

CONCLUSION & NEXT STEPS

Time Plan

Mining System Concept (Gantt Project)

Next Steps
Further analysis on each section as has been summarised
Several minor challenges to overcome Still to receive information for certain sections

Continue to complete analysis and link sections together Upon completion of the main elements described the operability and economic viability of the system can be assessed Next major deadline is final report hand-in on May 7th

Conclusion
All main elements of project progressing well Project has satisfied all aims and objectives thus far

Currently slightly behind schedule

Will change after exams We have a 2 week contingency built into schedule

Confident in delivering a high-quality final project in May

Thank you for listening

Any Questions?