Embed Size (px)
Citation preview
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
2
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
3
Celebrating over 30 years of metal-seated ball valve innovation
4
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
5
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
6
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
7
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
+
8
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
9
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
10
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
11
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
12
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
13
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
14
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
Craig Bekins
Key Account Manager - Mining
+1 514 748 7748 x5023
www.velan.com
/VelanInc
@VelanInc
/VelanInc
Follow us!
