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
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 2
Celebrating over 30 years of metal-seated ball valve innovation 3
Installed worldwide in HPAL & POX applications Falconbridge Nickel Phelps Dodge Newmont Gold Sherritt Int’l. Moa Bay Lihir Gold Ltd. Nickel Gold Coral Bay I & II Taganito Nickel Goro Nickel Dynatech Centaur Mining Minara Ambatovy Nickel Cawse Nickel Murrin Nickel Nickel Nickel Most of HPAL plants in operation use Velan severe-service ball valves 4
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 5
Optimization and qualification of Velan proprietary Cr 2 O 3 -TiO 2 blend to mitigate risk in the field for 2007 megaproject Commercial blend VEL-CL proprietary blend Typically Typically > 750 HV 0.3 > 900 HV 0.3 > 6,000 psi > 10,000 psi Hardness, porosity, bond & shear strengths, compression & point load, thermal shock, wet abrasion, slurry erosion, and autoclave corrosion test @ 278 C (582 F) 6
Results (2017 field performance): in-service life of severe service ball valves limited by the protective coating Time in _ QtyX, Appl. Number service Comments (NPS, Cl.) of cycles (months) 3X slurry feed S 30-36 > 500 (10, 150) e v 12X feed pump suction e 30-36 > 200 Some with coating delamination and some cleaned (10, 300) r and placed back i 12X feed pump t discharge 12 to 24 > 150 (10, 600) y 6X autoclave discharge 6 to 12 ~ 50 Coating delamination and erosion of the ball & seat + (14, 600) New coating technology needed to reduce total cost of ownership 7
Two protective coating technologies being developed to improve Velan valve performance in HPAL plants Novel Ref. paper presented at ALTA 2013 optimized Vs. Additional test results Cr 2 O 3 -TiO 2 blend Industrialisation & crack-free optimization VEL-18 VEL-CL Novel optimized blend Proprietary 2007 blend Ref. paper presented at ALTA 2006 Metallurgical Test results bond Field test RMH 8
4-point bending test results: VEL-18 provides higher resistance to crack propagation and spalling compared to VEL-CL Set-up Toughness resistance VEL-CL VEL-18 AE sensor Coupon 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 9
Custom designed tribo-corrosion set-up to assess the synergy between corrosion and wear Set-up Test procedure H 2 SO 4 Designed to simulate severe service ball valves that operate in a corrosive environment 10
Tribo-corrosion test results: assess the synergy between corrosion and wear of VEL-18 versus VEL-CL Behavior Degradation mechanism after during before wear VEL-CL VEL-18 wear wear VEL-18 provides higher properties compared to VEL-CL 11
Over the course of 10 years, Callidus developed, optimized and field trialed a metallurgically bonded coating for Velan valves Development on RDG 10” trim going autoclave RMH 3” trim RMH 3” trim discharge MSBV after 12 months after 36 months produced & installed 2015 2017 2018 2014 2009 2010 2013 RDG 10” RDG 10” RMH 3” after 29 months developed after 12 months Field results on prototypes suggest longer time in service vs conventional thermal spray coating for similar applications 12
Tribo-corrosion test results by Velan: assess the synergy between corrosion and wear of VEL-18 vs RMH Behavior Degradation mechanism during after before wear RMH VEL-18 wear wear VEL-18 has more stable behavior during tribo-corrosion than RMH 13
Summary ▪ VEL-CL, Cr 2 O 3 -TiO 2 , 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 14
Contact us Follow us! Fadila Khelfaoui Corporate Engineer, Metallurgy www.velan.com +1 514 748 7748 x2313 /VelanInc fadila.khelfaoui@velan.com @VelanInc /VelanInc Craig Bekins Key Account Manager - Mining +1 514 748 7748 x5023 craig.bekins@velan.com
Recommend
More recommend
