Protective surface treatment roadmap for HPAL and POX ...€¦ · VEL-CL, Cr 2 O 3-TiO 2, coating...

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

NewmontGold

Sherritt Int’l.

Moa BayNickel

Dynatech

Ambatovy NickelNickel

Coral Bay I & II

TaganitoNickel

Centaur Mining

Cawse NickelNickel

Minara

MurrinNickel

GoroNickel

Lihir Gold Ltd.Gold

FalconbridgeNickel

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 @ 278C (582F)

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

of 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

optimized

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-18Novel 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 resistanceSet-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 wearduring

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-18VEL-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 20182014

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 wearduring

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-18RMH

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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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