Protective surface treatment roadmap for HPAL and POX applications - - - PowerPoint PPT Presentation

Protective surface treatment roadmap for HPAL and POX applications - Velan update

Fadila Khelfaoui, Luc Vernhes, Craig Bekins, Nicolas Lourdel, and Duke Tran Velan, Canada Dominique Poirier, NRC, Canada Gary Lantzke, Callidus Welding Solutions, Australia

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Agenda

1. Field experience with current thermal sprayed ceramic coating

▪ Velan proprietary blend to mitigate risk in the field for 2007 megaproject ▪ 2017 field performance results

2. Current status with new protective surface technologies

▪ Thermally sprayed coating ▪ Metallurgically bonded coating

3. Summary

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Celebrating over 30 years of metal-seated ball valve innovation

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Installed worldwide in HPAL & POX applications

Phelps Dodge Newmont

Gold

Sherritt Int’l. Moa Bay

Nickel

Dynatech Ambatovy Nickel

Nickel

Coral Bay I & II Taganito

Nickel

Centaur Mining Cawse Nickel

Nickel

Minara Murrin

Nickel

Goro

Nickel

Lihir Gold Ltd.

Gold

Falconbridge

Nickel

Most of HPAL plants in operation use Velan severe-service ball valves

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Velan valves in HPAL service

Customer feedback: more than 95% of the Velan valves are fulfilling the requirements of the most advanced and severe acid leaching plants

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Optimization and qualification of Velan proprietary Cr2O3-TiO2 blend to mitigate risk in the field for 2007 megaproject

Commercial blend VEL-CL proprietary blend Hardness, porosity, bond & shear strengths, compression & point load, thermal shock, wet abrasion, slurry erosion, and autoclave corrosion test @ 278C (582F)

Typically > 750 HV0.3 > 6,000 psi Typically > 900 HV0.3 > 10,000 psi

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Results (2017 field performance): in-service life of severe service ball valves limited by the protective coating

QtyX, Appl. (NPS, Cl.) Time in service (months) Number

• f cycles

Comments

3X slurry feed (10, 150) 30-36 > 500 Some with coating delamination and some cleaned and placed back 12X feed pump suction (10, 300) 30-36 > 200 12X feed pump discharge (10, 600) 12 to 24 > 150 6X autoclave discharge (14, 600) 6 to 12 ~ 50 Coating delamination and erosion of the ball & seat

New coating technology needed to reduce total cost of ownership

_ S e v e r i t y

+

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Two protective coating technologies being developed to improve Velan valve performance in HPAL plants

Novel

• ptimized

Cr2O3-TiO2 blend Metallurgical bond

 Ref. paper presented at ALTA 2013  Additional test results  Industrialisation & crack-free optimization  Ref. paper presented at ALTA 2006  Test results  Field test

VEL-CL

Proprietary 2007 blend

VEL-18

Novel optimized blend

Vs. RMH

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4-point bending test results: VEL-18 provides higher resistance to crack propagation and spalling compared to VEL-CL

A sample is deemed to fail if there is visual sign of spalliation.

Results suggest that VEL-18 will provide superior performance in the field Toughness resistance Set-up

VEL-CL VEL-18

Coupon AE sensor

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Custom designed tribo-corrosion set-up to assess the synergy between corrosion and wear

Test procedure Designed to simulate severe service ball valves that operate in a corrosive environment Set-up

H2SO4

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before wear during wear after wear

Tribo-corrosion test results: assess the synergy between corrosion and wear of VEL-18 versus VEL-CL

Behavior Degradation mechanism VEL-18 provides higher properties compared to VEL-CL

VEL-18 VEL-CL

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Over the course of 10 years, Callidus developed, optimized and field trialed a metallurgically bonded coating for Velan valves

2009 2010 2013 2015 2017 2018 2014

RMH 3” trim produced & installed RMH 3” after 12 months RMH 3” trim after 36 months RDG 10” developed RDG 10” trim after 12 months RDG 10” after 29 months Development on going autoclave discharge MSBV

Field results on prototypes suggest longer time in service vs conventional thermal spray coating for similar applications

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before wear during wear after wear

Tribo-corrosion test results by Velan: assess the synergy between corrosion and wear of VEL-18 vs RMH

Behavior Degradation mechanism VEL-18 has more stable behavior during tribo-corrosion than RMH

VEL-18 RMH

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Summary

▪ VEL-CL, Cr2O3-TiO2, coating is a field-proven proprietary blend suitable for HPAL applications ▪ VEL-18 coating provides higher hardness, bond strength, toughness, and tribo-corrosion properties compared to the current VEL-CL coating ▪ Fused coatings such as RMH/RDG offer a solution to the primary failure mechanism of spray coatings (spallation) as illustrated in field trials ▪ Both VEL-18 and RMH/RDG offer better mechanical and tribo-corrosion properties when compared to current available technologies ▪ Fully fused coatings meet the strength and mechanical properties required for severe service ball valves and are the optimal solution

Contact us

Fadila Khelfaoui Corporate Engineer, Metallurgy +1 514 748 7748 x2313 fadila.khelfaoui@velan.com Craig Bekins Key Account Manager - Mining +1 514 748 7748 x5023 craig.bekins@velan.com

www.velan.com /VelanInc @VelanInc /VelanInc

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