Leak detection and localisation for tailings pipelines

Metals like copper, silver, gold, platinum, cobalt, or lithium play a crucial role in the global shift towards green energy technologies aimed at reducing carbon emissions. These metals are essential components of fuel cells, batteries, solar panels or wind turbines, all of which are key drivers in the global energy transition. As demand for these metals increases, so do their commodity prices, which has made the extraction and processing of tailings – a byproduct of minerals production – more economically viable.

The tailings consist of a highly abrasive medium containing chemicals, ore waste and large quantities of water to turn it into an aqueous slurry that can be pumped. Transmission pipelines transport the slurry to specialised treatment facilities where its mineral residues can be recovered, turning waste to value.

However, transporting tailings presents its own set of challenges. The composition of the slurry makes transportation particularly difficult as it poses a significant risk to pipeline integrity. Due to the high solids content and its abrasive nature, the pipelines are subject to constant wear, increasing the likelihood of damage and leakage over time.

In the event of a leak, the tailings slurry can sandblast the pipeline, increasing the size of the leak and causing the pipeline to rupture rapidly. Due to the varying altitudes over which tailings pipelines run, leaks can result in uncontrolled slurry release and tailings lakes, causing extensive environmental damage and financial risk.

Risk factors for leakages in a nutshell

• Contamination: The chemical-laden slurry can contaminate soil and groundwater sources, leading to long-term ecological harm.

• Biodiversity loss: Local flora and fauna may be destroyed, severely impacting the surrounding biodiversity.

• High clean-up costs: The environmental cleanup and restoration efforts are extremely costly, and failure to respond quickly can lead to irreversible damage.

• High loss of product and revenue.

• Risk of damage to additional pipelines and equipment due to sandblasting.

Why leak detection matters

The serious environmental and operational consequences make pipeline leak detection essential for safe and efficient operations. An effective pipeline leak detection and location system (LDS) is the solution of choice to mitigate the risks associated with tailings transport. By swiftly detecting and locating leaks, operators gain the following benefits:

• Significantly reduced response times: The LDS enables operators to send their clean-up teams directly to the affected areas, reducing the time required to locate the leak.

• Avoiding environmental damage: Quick leak detection allows operators to take immediate repair and remediation measures to prevent product leakage and the spread of environmentally harmful sludge.

• Optimised clean-up effort: The faster the response, the more limited the damage, which reduces clean-up costs.

• Compliance with legal monitoring requirements: Highly accurate response to leaks provides additional safety in an emergency to prevent major environmental damage.