wear resistant options for high pressure acid …€¦ · callidus welding solutions perth, western...

Presented by:Gary Lantzke, CEO

Callidus Welding SolutionsPERTH, WESTERN AUSTRALIA

WEAR RESISTANT OPTIONS FOR HIGH PRESSURE ACID LEACHING (HPAL)

APPLICATIONS

2

WHO WE ARE

CALLIDUS WELDING SOLUTIONS PERTH, WESTERN AUSTRALIA

Melbourne

Sydney

Brisbane

Perth

Presenter

Presentation Notes

CWS Intro Non Ferrous Western Australia

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HIGH PRESSURE ACID LEACHING

• Started in 1998• Cheap extraction of

Laterite Ore 0.9% -1.7%

• 98% H2SO4, 240°C, 45 bar pressure


HPAL LOCATIONSMurrin MurrinRavensthorpeRio TubaTaganitoNew CaledoniaMadagascarTurkey

Murrin MurrinRavensthorpe

New Caledonia

Madagascar

Rio Tuba Taganito

Turkey

Presenter

Presentation Notes

Nickel Laterite History Locations – Map Process – 98% H2SO4 @ 250 deg C and 45 bar Titanium throughout the circuit

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TITANIUM APPLICATIONS IN HPAL


P

M P

P

PP

P

MM M MM M

01PU03AB

ACID

HP Steam HP Air

Vent to scrubber

HPAL Feed Storage Tank

LT

HT

MT

Autoclave

GEHO

HP

LP

MPP

Water

01TK01AB

Scrubber System

Pre Neut

Steam Piping Ti 12Pre Heaters E.B. TiInternal Equipment Ti 12

Ti 12 Agi BladesE.B. Gr. 2 LinerWeir WallsBatten StripsNozzle InsertsInlet & Outlet PipingSteam Injection piping

Blast Tubes Ti 12Ceramic Lined

Flow Control Valves Ti

Process Slurry Piping Ti 12

Presenter

Presentation Notes

Typical / Generic conditions (Dom) Erosion – Blades / Valves/ Pipes (Dom) Big pics , multiple slides

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First Stage Pre-Heater Comes in at 60degC - heated to approx 120degC

Second Stage Pre-Heater 120degC to 200degC

Third Stage PumpsIn at 1950kPa / 200degC - pressure increase to 4450kPag

Third Stage Pre-heaterSlurry contacted with 60bar steam - heated from approx 200degC to 230-240degC

AutoclaveAddition of acid in the 1st compartment is causes exothermic reaction raising the temp to approx255degC

Residence time approx 90min - operating pressure of 4450kPag @ 255degC

Flash Vessel 1 1950kPag

Flash Vessel 2 650kPag

Flash Vessel 3 Atmospheric / 99degC

Most erosive issues are caused by flashing at points in the process where the pressure drops sufficiently for a portion of the product to form steam (3 phase flow) – the increased volume causes a dramatic rise in the velocity. High velocity flow with entrained solids causes dramatic rates of erosion.

TYPICAL HPAL CONDITIONS


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EROSION


Critical Valves

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EROSIONLetdown Valves

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EROSIONAgitation Blades

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EROSIONPiping

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STANDARD SOLUTIONS

Ti O2 – A.P.S. Coating


Presenter

Presentation Notes

Low angle impingement Not a 100% dense coating Undercoating corrosion Coating spallation

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STANDARD SOLUTIONS

Ceramics

Presenter

Presentation Notes

Hard but brittle Thermal shock throughout the system

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TiN - A DEVELOPED SOLUTION

Presenter

Presentation Notes

A developed solution History Field Tests

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Can the surface of Titanium be

contaminated in a controlled way to produce a wear resistant surface

while still maintaining the material’s suitability to

corrosion service

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TITANIUM NITRIDE Applicable onto All titanium grades

Already developed and widely used on commercial pure, low alloy and near alpha titanium grades type Gr. 3, 12, 7, 9.

Method Conversion: the surface of the substrate is converted and result in a flat surface.

1.8 mm 1.1 mm


Presenter

Presentation Notes

First develop TiNi modify the surface of titanium my melting and control contamination

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TITANIUM NITRIDE Applicable onto All titanium grades

Already developed and widely used on commercial pure, low alloy and near alpha titanium grades type Gr. 3, 12, 7, 9.

Method Build up: Addition of filler material during the conversion process

4.3mm2.7mm


Presenter

Presentation Notes

Second stage is the addition of wire via robotic welding whilst controlling the contamination parameters

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Chemical Formula TiN

Hardness 300 – 900 HV eq. 30 – 67 Rockwell C

Fracture toughness (1) 35 – 80 Mpa.m1/2

Thickness of converted material 1 – 4 mm using conversion method1 – 6 mm using build up method

Converted compound 20 to 90%

Microstructure Dendritic fineDendritic coarse Rod-like

(1) Fracture toughness is measured by the indentation technique. In this application fracture toughness is an indicative value and used for comparison amongst TiN material

TITANIUM NITRIDE - PROPERTIES


Presenter

Presentation Notes

Hardness is a function of percentage of conversion Hardnesses can be designed between 300 and 1150 Hv

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TITANIUM NITRIDE - MICROSTRUCTURE

Fine dendritic structure close to the surface (right on the picture) and coarser structure further away from the surface

Rod-like TiN structure usually observed close to the TiN / substrate interface where the TiNconcentration drops (top corners are the titanium substrate)


Presenter

Presentation Notes

For the technical amongst us typical TiNi microstructures at substrate interface Talk about fusion zone defects and fracture mechanics

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TITANIUM NITRIDE - HARDNESSHardness profile of two TiN-B (Build up) and two TiN-C (Conversion) samples

200

300

400

500

600

700

800

900

0 1 2 3 4 5

Har

dnes

s H

V5

Distance below surface (mm)

TiN-B1

TiN-B2

TiN-C1

TiN-C2

Presenter

Presentation Notes

Hardness variations and issues.

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TITANIUM NITRIDE –WEAR PROPERTIES


Figure 1: Comparison of hardfaced nonferrous alloys and carbon steel reference materials

using ASTM G65 Practice B (source: ASM Handbook Ed 10 Vol 18, p762).

TMH

TiNi 012

TiNi 009

Ti12 (170 mm3)

Presenter

Presentation Notes

Comparative RWAT G65 data TMH is TiNi build up, TiNi 009 and 012 in house WPS names

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Without TiN

With TiN

Strainer basket for acidic slurry application (in HPAL process)


Presenter

Presentation Notes

One 7 month campaign same client same conditions

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HOW DO WE DO IT ?


Presenter

Presentation Notes

Precise parameter control 5 fully integrated welding robots modified for purpose

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CURRENT APPLICATIONS

Agitation Blades


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CURRENT APPLICATIONSPipes

Presenter

Presentation Notes

Between 3mm and 10mm thick Life extension up to 6 times unprotected elbows depending on speed of process

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Wear Plates

Presenter

Presentation Notes

Used to protect EB clad High cost vessel internals i.e. impingement blocks

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Valve Parts

Presenter

Presentation Notes

High cost trims Ceramic replacement in some areas

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Cone Dispersion

Presenter

Presentation Notes

Preheat circuit Life extension 2-3 times

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WHERE TO NOW ?


Presenter

Presentation Notes

Importance of surface profile in wear performance Bead direction

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Optimization of parameters for a flat deposition using build up method.

WHERE TO NOW ?

4.3mm2.7mm

2.7mm2.2mm


Presenter

Presentation Notes

Importance of surface profile in wear performance Bead direction placement

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Reduction in relief checking

WHERE TO NOW ?


Presenter

Presentation Notes

Benefits of pre heat Research into PWHT

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WHERE TO NOW?Combination approaches – Vent Plug


Presenter

Presentation Notes

Ceramic plug head held in by titanium Current cause of failure erosion of the titanium encapsulation

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WHERE TO NOW?Combination Approaches - Agitation Blades


Presenter

Presentation Notes

Combination approaches

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WHERE TO NOW?

New markets

OIL AND GASAUTOMOTIVE


Presenter

Presentation Notes

Breakpad Usage, Seawater Deluge

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Gary LantzkeC.E.O.Perth Western AustraliaDirect +61 8 9441 5903Mob +61 439 900 [email protected]

CONTACT US

wear resistant options for high pressure acid …€¦ · callidus welding solutions perth, western...

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