DERAKANE Based Solutions for Metal Processing Industries Communications

Transcription

1 DERAKANE Based Solutions for Metal Processing Industries Communications Guy Schneider Moscow, October 2014 Registered trademark, Ashland or its subsidiaries, registered in various countries Trademark, Ashland or its subsidiaries, registered in various countries

2 Mining Overview. Main metals recovered: Nickel, Copper, Uranium, Cobalt, Zinc, Rare Earths. Typical Metal Recovery Processes Smelting Solvent Extraction (SX) Electrowinning (EW) Acid Leaching. 2

3 Mining processes 3

4 Composites Offer Many Advantages As A Material Of Construction In Mining Operations Broad chemical resistance to process chemicals in metals recovery Not subject to galvanic corrosion Excellent non-conductive properties for electrolytic cell area High strength to weight ratio Easy & quick maintenance Ashland resins have over 50 years of proven performance in corrosion applications 4

5 Typical Composite Applications In Mining And Metal Processing Electrowinning cells Electrostatic precipitators Extractors Duct, fans, and dampers Scrubbers Fume stacks and stack liners Cell covers Dust control systems Storage tank Settling tanks Piping Pumps and pump bases Cooling towers Grating, railings & structural supports Floor coatings Reinforced linings on steel or concrete structures 5

6 Types Of Composites Used In Mining Applications Total structure designed and manufactured with composite (full FRP) DERAKANE resin with glass flake applied as reinforced liner on steel or concrete substrate Thermoplastic lined composite Polymer concrete (resin, sand, and aggregate formulation) 6

7 Solvent Extraction (SX) Process Allows extraction of metal from oxide form of ore Allows economical processing of low grade ore First step: Leaching with acid. Next step: Vigorously mixed with kerosene based solvent with organic chemicals to extract minerals. Final step: Mixing and settling stage where minerals is transferred for organic form to aqueous solution Aqueous solution is then transferred to electrowinning cells for metal recovery 7

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9 Six CCD vessels (75 m dia) with FRP panels and launders. Another 12 mixer settlers. 9

10 Large tank (10m diam, 15m high) for HCl storage, made with Derakane*

11 Abrasion Resistant Piping 11

12 Composite Applications In Electrowinning Operation Electrowinning cells Grating and structural supports Electrolytic baths Piping Spent electrolyte tanks 12

13 Electrowinning House in Africa 13

14 Applications Of Composites In Smelting Operations Electrostatic precipitators Duct, fans, and scrubbers Grating and structural supports Free standing stacks and stack liners inside concrete chimney 14

15 Case History: Zhuzhou Zinc Smelter Largest zinc smelter in China (635K MT of zinc and lead in 2013). Acid leach tanks designed by Outotec and fabricated by Zhongfulianzhong (ZFLZ) 15

16 Goro Project, New Caledonia 16

17 Vale Inco Nickel Newfoundland, Canada 17

18 Long Harbour 64 large diameter tanks (some as large as 14 m dia x 17 m tall) 18

19 Boleo project Mexico Dozens of FRP processing vessels and storage tanks. Miles of acid and abrasion resistant piping. Six CCD vessels (75 m diameter). 19

20 MolyCorp Mountain Pass Rare Earth processing facility in CA near Las Vegas. Aggressive extractive reagents Remove rare earth elements from ore Separate rare earth elements from each other Dozens of extraction / separation tanks in hydromet 20

21 Keys To Successful Application Resin selection Design based on type of composite used in manufacture of equipment Clear specifications and detailed operating conditions Quality fabrication As with any material of construction inspection of equipment 21

22 Summary and Conclusions FRP has been used successfully for over 50 years as a corrosion resistant material of construction in a wide variety of mineral processing applications FRP equipment is inherently corrosion resistant to acid based hydromet processes Many applications are better handled by FRP than metal alloys FRP is a more economical choice than metal alloys or rubber lined steel 22