1. Ingeniería

PATH
Composites in Mining and
Minerals Processing
Lucy Cranitch
PATH
Lucy Cranitch
PATH
Outline
1 A
1.
Application
li ti
and
d
Opportunities for
Composites in Mining
• Vessels
• Pipelines
• Infrastructure
2. Materials
• What Are Composites
• Properties
• Cost Comparison
• Failure Modes
Questions
Lucy Cranitch
3 Working With Composites
3.
• Design
• Manufacture
• Transport
• Installation
• Use
• Inspection & Testing
Questions
PATH
Composites
•
•
•
•
•
Fibreglass
FRP = Fibre
b e Reinforced
e o ced Plastic
as c
GRP = Glass Reinforced Plastic
GRE = Glass Reinforced Epoxy
CFRP = Carbon Fibre Reinforced Plastic
Lucy Cranitch
PATH
Application and Opportunities
for Composites in Mining
Minerals Processing Vessels
Lucy Cranitch
PATH
Mineral Processing Vessels
Zinifex. Sulphuric Acid Plant.
Tank
Stack
Mercury
M
Launders
Removal Tower
Gas Cooling
Tower 10%
S l h i acid/
Sulphuric
id/
zinc sulphate
Clarifier Cover
Cover. Water
Reactor Tanks
Gas Flue valves
Electrolytic Cells Vapour + acid 70oC
Copper Sulphate To 180oC
Lucy Cranitch
PATH
Pipelines
•
Western Corridor Recycled
Water Pipeline
•
Underground
g
p
pipeline
p
to take
treated water industry.
•
Output: up to 282 ML/day.
•
Pipe: Flowtite
•
Length: 80 km
•
Diameter: 1000 and 1200 mm
•
Pressure: 1.6 and 2.5 MPa
•
Standard: AS 3571
•
Other composite parts: Bends
and Tee Pieces
Lucy Cranitch
PATH
Pipelines
in Iron Ore
•
Transport iron ore as a slurry
from mine to coast
•
Return water to mine
•
Length: 290 km
•
Diameter: 600 mm
•
Pressure: up to 5 MPa
•
Standard: ISO14692 and AS
2885
•
Drivers: salt & oxygen in water,
GRP cheaper than steel
•
Challenge: Abrasive solids
Lucy Cranitch
PATH
Pipelines in Bore-fields
•
Bore-fields between iron ore mine and coast
•
Top up pipeline with water
•
W t may be
Water
b ponded
d db
between
t
mine
i and
d coastt
•
Diameter: 450 mm
•
Pressure: up
p to 5 MPa
•
Drivers: salty water, composite can be cheaper than
HDPE
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PATH
Mining Infrastructure
Mine Vent Ducting
Rock Bolts
Lucy Cranitch
PATH
Mining Infrastructure
Truck bodies & panels
Wash plant pipes
Ladders, handrails, steps, platforms
Drill Rods
St
Storage
containers
t i
– water,
t fuel
f l
Lucy Cranitch
PATH
Mining Infrastructure
Grating
Cable Supports
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Handrails
Stairs
Rebar
Roof and Wall Sheeting
PATH
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Courtesy of GCDA
PATH
Outline
1 A
1.
Application
li ti
and
d
Opportunities for
Composites in Mining
• Vessels
• Pipelines
• Infrastructure
2. Materials
• What Are Composites
• Properties
• Cost Comparison
• Failure Modes
Questions
Lucy Cranitch
3 Working With Composites
3.
• Design
• Manufacture
• Transport
• Installation
• Use
• Inspection & Testing
Questions
PATH
Materials
Reinforcement
1. support load
Resin
1. bond fibres
together
2 distribute forces
2.
3. barrier to water,
chemicals, UV, abrasion
Lucy Cranitch
Carbon
Highest specific stiffness
Kevlar
Highest specific strength.
Impact
pact resistance
es sta ce
Glass
High strength, low price
Epoxy
Adhesion, mechanical
properties
Vinyl Ester
Chemical resistance,
toughness
Polyester
Inexpensive
Price
Price
PATH
Materials – Reinforcement Forms
Type
Form
Function
E Glass
Continuous Fibres
Unidirectional Fabric
Strength in 1 direction
Fabrics e.g. woven
roving, cloth,
stitched fabric
Strength in 1,2 or 3
directions
Fibres
Chopped Strand Mat
Strength in all
directions
Inter-laminar adhesion
Tissue/Veil
Supports resin rich
layer – provides
moisture & chemical
barrier
C glass,
synthetic
or carbon
Lucy Cranitch
PATH
1
2
3
Lucy Cranitch
PATH
Materials
Resins
M t l
Metals
•
•
•
•
Carbon Steel
Stainless Steel
• 304
• 316
• 317
Titanium
Al i i
Aluminium
Lucy Cranitch
•
•
•
Epoxy - mechanical
Vinyl Esters – chemical properties
• Bisphenol Vinyl Ester – standard
• Novolac Vinyl Ester – high performance
Polyesters • Orthophthalic – low cost
• Isophthalic - water
• Terephthalic - fuel
• Chlorendic - chemical
• Bisphenol A Fumarate - chemical
PATH
Manufacture
Hand Lay Up
Lucy Cranitch
Filament Winding
Pultrusion
PATH
Outline
1 A
1.
Application
li ti
and
d
Opportunities for
Composites in Mining
• Vessels
• Pipelines
• Infrastructure
2. Materials
• What Are Composites
• Properties
• Cost Comparison
• Failure Modes
Questions
Lucy Cranitch
3 Working With Composites
3.
• Design
• Manufacture
• Transport
• Installation
• Use
• Inspection & Testing
Questions
PATH
Mining Industry Drivers
COST
• Extend life of assets – leads to less capital cost
• Reduce maintenance - can be as high as 50% of operating costs
• Increased cost of steel and fuel
SAFETY - Fire, Corrosion, Lift loads, Electrocution
• Less hazardous materials and designs
TIME
• Quicker installation & start up
• Long
L
d
delivery
li
titimes ffor other
th materials
t i l whilst
hil t need
d tto iincrease
production now.
• Increase plant running time
• Reduced failure & thus downtime
Lucy Cranitch
PATH
Why Change Materials?
•
•
•
•
Don t change unless impetus.
Don’t
Mining Industry is conservative as failure is extremely expensive –
shutdowns cost at least $1 million per day.
q p
is balanced against
g
benefits
Cost of equipment
Need solutions to existing problems
Mining Industry Drivers
Composite Strengths
Reduce Costs
Corrosion Resistance
Increase Safetyy
Non Conductive or Conductive
Increase Uptime
Light Weight
Lucy Cranitch
PATH
Properties of Composites
Materials – Chemical Properties
Polyester
Resin
Vinyl Ester
Resin
Acids (weak)


Acids (strong)
x

Bases
x

Solvents


S lt Solutions
Salt
S l ti


pH 0-14
Can also be used for potable water if resin is certified for AS4020
Lucy Cranitch
PATH
Materials – Chemical Properties
•
•
•
•
•
Tanks
T
k & Process
P
Vessels
V
l
Pipelines
Grating & Handrails
C
Conveyors
Trucks & Mobile Equipment
Mining Industry Drivers
Cost Reduction
* Extend life of assets
* Reduce maintenance – no painting
Safety
y
* No corroded gratings or handrails
Increase Plant Running Time
* Reduced failure & thus downtime
Lucy Cranitch
PATH
Corrosion Resistance can Increase Safety
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PATH
Materials – Chemical Properties
Incitec Pivot - Mt Isa
Sulfuric Acid Plant continuously operating since 1999
• Sulfur dioxide and sulfur trioxide gas
• Sulfuric acid.
• 68oC
Settlers
Piping
Radial Flow
Scrubber
Gas Cooling
Tower
Ducts
Inlet Manifold
Lucy Cranitch
PATH
Materials – Chemical
Properties
Jamison
Cells
BHP Billiton – Olympic Dam
• Uranium solvent extraction plant
• Precipitation and calcination plant
• Copper solvent extraction plant
Chemicals
• ammonium sulphate
• sulfuric acid
• sodium carbonate
• hydrogen peroxide
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Mixer
Settlers &
Internals
Tank
PATH
Materials - Mechanical Properties
Material
Glass
Composite
Mild
Steel
Stee
Aluminium
Density
(g/cm3)
1.5-2.5
7.8
2.7
Tensile
T
il Strength
St
th
(MPa )
50 700
50-700
410 480
410-480
80 480
80-480
Tensile Modulus
(GPa )
10-60
190-210
70
Tensile
Elongation (%)
1.6-2.1
22-37
2.5-23
Lucy Cranitch
PATH
Materials - Light Weight
Composites weigh 6 x less than
steel for the same strength
•
•
•
•
•
Electrical guarding (lift loads)
Hatches (lift loads)
Tanks & process vessels (at
Installation)
Conveyors (fuel saving)
T k & Mobile
Trucks
M bil E
Equipment
i
t
(fuel saving)
Lucy Cranitch
Mining Industry Drivers
Cost Reduction
* Reduced installation costs
* Reduced fuel cost
Safety - Lift loads
* Less hazardous materials & designs
Increase Plant Running Time
* Quicker installation & start up
PATH
Materials - Light Weight
Lucy Cranitch
PATH
Materials - Abrasion Properties
Can be improved by:
• 3-5% hard fillers such as silicon carbide helps. Either in a
coating or part of the corrosion barrier
• Flooring or trowel on pastes can have up to 40% silicon
carbide or other abrasion resistant fillers.
• Use of a veil, particularly a carbon veil increases abrasion
resistance.
Lucy Cranitch
PATH
Materials – Thermal Properties
• Max temp of composites is determined by HDT of resin.
• AS2634 - HDT of the resin shall be not less than 20°C above the
design temperature.
• Some composites can be used up to 250°C
Isophthalic
p
Polyester
y
Resin
(ESTAREZ® 3-491P)
Standard Vinyl
y
Ester Resin
(HETRON® 922)
High
g Performance
Vinyl Ester Resin
(HETRON® 970/35)
HDT at 1.82 MPa (°C)
85
100
149
Elongation to Break (%)
2.5
6.5
3.5
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PATH
Materials – Thermal Properties
Temp (C)
Tensile Strength of Resin
(MPa)
-43
117
25
109
65
147
95
147
120
121
150
74
Coeff-thermal expansion deg C x 10-6
Lucy Cranitch
Mild Steel
Composite
12
5-35
PATH
Materials – Thermal Properties
Delta Electrolytic Manganese Dioxide plant
• Electrolytic Tanks and 60
El t l ti C
Electrolytic
Cells
ll
• 4% sulphuric acid at 97-100°C
• Some tanks cycle between 97°C
and ambient every 6 hours
• Larger tanks are typically between
60°C and 70°C
• HETRON® 980 Resin
• After 10 y
years of continuous
operation, the resin was still
performing well, although some
mechanical issues had to be
addressed
Lucy Cranitch
PATH
Materials – Non Conductive
Composites are natural insulators
Rio Tinto , Aluminium Smelter
• Claustra Walls in Pot Room
• Telescopic tools.
tools
• Electrowinning
Materials Requirements
• electrically insulating.
• fire retardant.
• corrosion resistant
resistant.
• lightweight.
• pigmented.
• high physical strength.
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Mining Industry Drivers
* Safety – no electrical sparking,
no electrocution
PATH
Materials – Conductive
Composites can be made
conductive
•
•
•
Static charge can build-up in
stacks,, tanks,, piping
p p g and ducts
EMP’s and solvent extraction
require conductive laminates
Grounding composite
equipment is critical.
Mining Industry Drivers
Cost Reduction
* Reduced failure = reduced rebuild cost
Safety
* Reduced incidence of fire
Lucy Cranitch
Increase Plant Running Time
* Reduced failure & thus downtime
PATH
Materials – Conductive
•
Construction
• Carbon Surfacing Veil saturated with resin containing 5 -15 % w/w
carbon/graphite filler.
• Ensure continuity across joints where applicable
• Grounding
g must be p
provided through
g to the outside of the
equipment. Titanium or stainless steel bolts and a putty made from
the carbon/graphite filler
• Test – Megger
gg BM80 or BM 2580
Lucy Cranitch
PATH
Materials – Fire Properties
•
•
•
•
•
Composites will burn but fire retardant composites available
including Hetron FR992, Hetron 197 or Derakane 510A and 510C
Ducts for flammable gases may require fire retardant resin for
internal layer.
y
Tanks may require fire retardant resin for external layer.
Tested to AS1530 pt3, cone calorimeter or ASTM E-84 flame
spread of ≤25 (Class 1)
Fire retardants can reduce chemical resistance
Resin
HETRON ® 197
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Tendency
y
to Ignite
12
Heat
Developed
0
Flame
Spread
1
Smoke
7
PATH
Materials – UV Properties
•
•
•
•
UV can chalk outside layer of composites or degrade composites over
time
A pigmented layer will protect composites
Since pigmented layer limits inspection, it should be applied after all
QA complete
Alternatively UV inhibitors can be used in the resin
Lucy Cranitch
PATH
Material Properties - Drivers for Composite Use
Corrosion resistance
 Long life with low maintenance 
reduce cost
 Safety
Non Conductive or
C d ti as required
Conductive
i d
 Safety
High strength and light
weight
 Installation – quicker – save time,
less hazardous, reduce cost
 Safety
 Large unsupported covers possible
Lucy Cranitch
PATH
Cost Comparison
•
•
•
•
•
Australian
A
li C
Company
Tank: 3 m diameter, 5 m high
70% Sulphuric Acid
Wall thickness 6 mm in steel and 15 mm in composites
Specific Gravity of steel 7.8 cf 1.6 for composites – tank half the
weight
g in composite
p
Tank Material
Tank Fabrication Cost
Cost Ratio
SAF 2205 Stainless Steel
$130,467
1.3
316 Stainless Steel
$110,897
1.1
Mild Steel
$58,710
0.6
Composite
$99,720
1.0
Lucy Cranitch
PATH
Cost Comparison
•
•
•
•
Pipe
Diameter 150 mm
P
Pressure
700 kPa
kP
12 m length, 1 flange, 1 elbow 90 degrees, 2 joints/welds, 2 mild
steel supports
Pipe Material
Fabrication
Installation
Supply &
Installation
SAF 2205 Stainless Steel
6.3
1.1
3.6
316 Stainless Steel
1.6
1.1
1.4
Composite
1.0
1.0
1.0
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PATH
QUESTIONS?
Lucy Cranitch
PATH
Outline
1 A
1.
Application
li ti
and
d
Opportunities for
Composites in Mining
• Vessels
• Pipelines
• Infrastructure
2. Materials
• What Are Composites
• Properties
• Cost Comparison
• Failure Modes
Questions
Lucy Cranitch
3 Working With Composites
3.
• Design
• Manufacture
• Transport
• Installation
• Use
• Inspection & Testing
Questions
PATH
Failure Modes
•
•
•
•
•
Poor QA during production
Chemical degradation
E i iin pipes
Erosion
i
Cracking and Delamination
Impact
Lucy Cranitch
PATH
Failure Modes - QA
Poor QA During Production
• Balance between Quality and Price
• Resins which are not as corrosion resistant
• Fibre layout not consistent
• Laminate too thin (hydro testing fail)
• Not cured properly (wrong/insufficient
(
/i
ffi i t catalyst,
t l t initiator,
i iti t promoter
t and/or
d/
temperature. Postcure)
•
•
Insufficient overlaps in laminate and at joints
Insufficient inspection and testing
Lucy Cranitch
PATH
Failure Modes – Blisters & Softening
• Fluids entering the laminate creates pressure.
• Pressure causes the laminate to detach & blister.
Laminate
Fluid
Correct resin and tissues help minimise this. “The resin rich layer shall be of a minimum
thickness of 0.25 mm and shall contain ‘C’ Glass surfacing tissue or synthetic fibres
such as polyester or acrylic fibres of minimum dry thickness 0
0.25
25 mm
mm. Minimum resin
content by weight shall be nominally 90%.” [AS2634]
Lucy Cranitch
PATH
Failure Modes - Chemical Degradation
•
•
Splash of 95%
sulphuric Acid
Wrong material in
this environment
Or
• Process conditions
outside of
specification
Lucy Cranitch
PATH
Failure Modes – Erosion of Pipes
Can be improved by:
• 3-5% hard fillers such as silicon carbide helps. Either in a
coating or part of the corrosion barrier
• Use of a veil, particularly a carbon veil increases abrasion
resistance.
Lucy Cranitch
PATH
Failure Modes – Delamination & Cracks
•
•
•
At flange faces
At corners
At secondary joins
•
Procedure for flange
tightening
Avoid sharp corners
Don’tt over pressurise
Don
pipes
•
•
Lucy Cranitch
PATH
Failure Modes - Impact
• Effects structural integrity but can also crack the internal resin
• During transport
• use correctt supports,
t cradles,
dl
padding
ddi and
d stiffening
tiff i d
devices
i
• During installation
• use lifting lugs, webbing or soft slings
• avoid shock loads and sliding
• ensure supports are correct
• During use
• avoid hydroblasting
• take care with forklifts etc.
Lucy Cranitch
PATH
Outline
1 A
1.
Application
li ti
and
d
Opportunities for
Composites in Mining
• Vessels
• Pipelines
• Infrastructure
2. Materials
• What Are Composites
• Properties
• Cost Comparison
• Failure Modes
Questions
Lucy Cranitch
3 Working With Composites
3.
• Design
• Manufacture
• Transport
• Installation
• Use
• Inspection & Testing
Questions
PATH
Design Life
•
•
•
It depends on the conditions of use
Design life of a minimum 20 years continuous operation is typical in the
mining
g industry
y
Design life up to 100 years now specified for water and waste industry
Examples:
p
• Bleach washer hoods were used for 17 years in a Canadian pulp and
paper mill.
• High performance polyester have operated in chemical service for 25
years and still been in sound condition
condition.
• Underground fuel storage tanks. Isophthalic resin. Exhumed after 25
years service and shown little or no physical or chemical degradation.
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PATH
Design Life Example
Uptime
i
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PATH
Design – Resin Selection
Resin Selection Guides
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PATH
Design - Standards
Pipes and
Pi
d Ducts
D t
•
AS 2634. Australian Standard for “Chemical
Plant Equipment made from Glass-Fibre
Reinforced Plastics (GRP) based on
Thermosetting Resins”
•
AS 2566 Buried Flexible Pipelines
•
BS 7159 Code of Practice for Design and
Construction of Glass Reinforced Plastics (GRP)
piping systems for individual plant sites.
•
BS 6464 Reinforced Plastic Pipes, Fittings and
Joints for Process Plants
•
ISO 14692 Petroleum and natural gas industries
— Glass-reinforced plastics (GRP) piping. [Use for
high pressure or SX pipes]
Lucy Cranitch
PATH
Design Detail
Pressure
•
•
API 15 HR Specification for High Pressure
Fiberglass Line Pipe – 2001 cover pipes
rated for 3.45
3 45 MPa to 34
34.5
5 MPa
MPa.
18 MPa pipe typically available for oil and
gas.
Supports
•
•
•
•
For pipes and ducts, BS 6464 contains information on installation
including supports, guides and anchors.
Pipe
p support
pp spacing
p
g is important
p
to limit deflection,, for example
p using
g
a maximum deflection to span ratio of 1:300.
A minimum contact arc of 120° under the pipe is typical.
Rubber packers can help
Lucy Cranitch
PATH
Design - Standards
Tanks
T
k and
d Process
P
Vessels
V
l
• AS2634. Chemical Plant Equipment Made From Glass-Fibre
Reinforced Plastics (GRP) Based on Thermosetting Resins.
• BS4994. Design and Construction of Vessels and Tanks in Reinforced
Plastics
• BS EN 13121 GRP Tanks and Vessels For Use Above Ground
• BS EN 13923 Filament Wound FRP Pressure Vessels – Materials,
design, manufacturing and testing
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PATH
Design Detail - Tanks and Process Vessels
Support
• Concrete slab or alternative
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PATH
Design - Joints
Butt and strap
• Strength must be at least equivalent to
parent material
• Laminate internal surface where
accessible
• Widths are g
given in standards
• Hand lay-up design thickness
• Resin seal all cut ends
Lucy Cranitch
PATH
Design - Joints
Branch
B
h joints
j i
• Similar
Requirements to
b tt and
butt
d strap
t
joints
• Need additional
reinforcement
i f
t to
t
replace strength
of cut out.
Lucy Cranitch
PATH
Design - Joints
Flanges
• Composite flanges
• Compatible with steel
• ANSI Dimensions
• Full flat faced suggested. Flatness
important
• Steel backing rings can be used
• Washes under nuts
• Care with bolt torque
• Care with nozzle projections (not
too far)
• Resin seal all cut outs
Lucy Cranitch
PATH
Tank Lining
•
Line concrete or steel tank with composites
Dual Laminate Systems
y
– Line Fibre Composite
p
tank with plastic
p
• Polypropylene
• PVC & CPVC
• Fluorinated – PVDF, ECTFE, FEP
• Test for suitability (corrosion & erosion) – in exact solution, under load
• When acting as corrosion barrier - minimum bond strength of 7 MPa in
direct shear & 5 N/mm width in peel.
p
• Materials usually come glass backed for laminate adhesion
Lucy Cranitch
PATH
Concrete Floor and
Bund Protection
Concrete
Primer - Resin + 10%
Styrene Monomer.
Three layers of 450
g/m2 powder bound
chopped strand mat
1 mm
y of
One resin rich layer
20 g/m² surface tissue
3 mm
1 mm
0.5 mm
Lucy Cranitch
Top coat - Resin
+ 0.5% Wax in
Styrene
Sand non
slip surface
PATH
Concrete
Primer - Resin + 10%
Styrene Monomer.
Base coat - Resin +
graded silica sand
aggregate.
1 mm
5 - 15 mm
Top coat - Resin +
0.5% Wax in Styrene
0 5 mm
0.5
Lucy Cranitch
Concrete Floor and
Bund Protection
Sand non
slip
p surface
PATH
Concrete Floor and Bund Protection
Olympic Dam - 12,000 m2 of concrete protection across site
Particularly in solvent extraction area
Chemical Environments
1
1.
S l h i acid,
Sulphuric
id pH
H0
0.8
8
2.
Ammonia and ammonium
sulphate
3.
Ethanol
4.
Kerosene
5.
Caustic soda & sodium
carbonate, pH 12-13
6
6.
Chlorides
7.
Fluorides
8.
Sodium chlorate
Lucy Cranitch
PATH
Working With Composites
•
•
•
•
•
•
Design
Manufacture
T
Transport
t
Installation
Use
Inspection and Testing
Lucy Cranitch
PATH
Manufacture - Post-cure
•
•
Must post-cure using heat, when used in aggressive corrosive
applications
P t
Post-cure
gives
i
a more complete
l t cure (further
(f th crosslinking).
li ki ) This
Thi
gives higher mechanical properties, heat distortion temperature
(HDT) & chemical resistance.
•
Barcol hardness of at least 90% of datasheet value.
Lucy Cranitch
PATH
Transport
During transport use correct support
support, cradles
cradles, padding and stiffening
devices
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PATH
Installation
Installation should use correct supports
supports, lifting lugs
lugs, webbing or soft
slings, avoid shock loads, avoid sliding
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PATH
Use
• Avoid hydroblasting or use lower pressure
• Avoid impact from equipment and machinery
• Ensure process control
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PATH
Inspection and Testing
Non-Destructive Methods
• Visual Inspection
• Barcol Hardness Testing
• Cure
C
T
Testing
ti with
ith A
Acetone
t
• Tap Testing
• Ultrasonic Testing
• Acoustic Emission
Destructive Methods
• AS 3572 Plastics – Glass filament reinforced plastics (GRP) – Methods
of test
test.
• Mechanical tests – tension, compression, shear, fatigue, creep, impact,
modulus, stress & strain to break
• Microscopy– Optical, Scanning Electron Microscopy
• Accelerated
A
l t d ageing
i – in
i chemicals,
h i l ffatigue,
ti
stress,
t
h
heat,
t UV
Lucy Cranitch
PATH
Outline
1 A
1.
Application
li ti
and
d
Opportunities for
Composites in Mining
• Vessels
• Pipelines
• Infrastructure
2. Materials
• What Are Composites
• Properties
• Cost Comparison
• Failure Modes
Questions
Lucy Cranitch
3 Working With Composites
3.
• Design
• Manufacture
• Transport
• Installation
• Use
• Inspection & Testing
Questions
PATH
Summary
Composites tend to replace more traditional materials including steel
and concrete:
• In corrosive environments
• Where electrical insulation is required
• Where light weight is required
• Where low life cycle cost is desired
With correct resin selection, materials design and
manufacture, composite assets can give lifetimes of 20
to over 100 years depending on the application.
Lucy Cranitch
PATH
Questions?
Dr Lucy Cranitch
Materials Scientist
PATH
Practical And Timely Help
Consulting in composites,
plastics, rubber & coatings
M: 0420 664 631
E: [email protected]
Lucy Cranitch