Mining & Metals

Leaching – Material Selection

Benoît Martin | Product Portfolio Manager | December 13th, 2018

 THE SAFE HARBOR STATEMENT UNDER THE US PRIVATE
SECURITIES LITIGATION REFORM ACT 1995

This presentation may contain forward-looking statements,

including but not limited to, projections of financial developments,
market activities or future performance of products and solutions,
containing risks and uncertainties. These forward-looking
statements are subject to change based on known or unknown risks
and various other factors, which could cause the actual results or
performance to differ materially from the statements made herein.

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Summary

 References
 Key Factors
 Material Selection

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References

 Leaching Solution (medium Cl content) – MOC: DSS

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References

 Leaching Solution (medium l content) – MOC: 254 SMO

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References

 Leaching Solution (medium Cl content) – MOC: 254 SMO / SDSS

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References

 Leaching Solution (high Cl content) – MOC: Hastelloy / Titanium

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References

 Leaching Solution (high Cl content) – MOC: Titanium

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References

 Leacaching Solution (high Cl content) – MOC: - Titanium

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Summary

 References
 Key Factors
 Material Selection

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Key Factors

 Material properties

 Temperature
 Maximum liquid temperature < 50°C

 Chloride content (Cl-)

 Use of seawater
 Chloride content in Copper ores
 Addition of Cl to improve leaching process performance
 Up to 200 g/l and more

 Composition of pumped liquid

 Fe3+ content
 Na+ content
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Summary

 References
 Key Factors
 Material Selection

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Material Selection

 Material Properties

 PREN is a reference number used to quantify the pitting resistance of stainless

steels and is based on the material chemical composition
– Calculation: PRE = % Cr + 3,3 % Mo + 16 % N
– Higher PRE value leads to better resistance to corrosion
– Ex.: SDSS PREN (~42) > 254 SMO PREN (~40)

 Mechanical properties are important for high energy pumps

– 3% plastic limit has an impact to cracks development in case of abnormal operation
– Ex.: SDSS plastic limit (450 Nm) > 254 SMO plastic limit (260 Nm)

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Material Selection

 Material Properties

 Critical Pitting Temperature (CPT)

– Pitting resistant material at low temperature can become pitting sensitive at higher
temperature
– CPT is the temperature at which pitting corrosion takes place

CRITICAL PITTING TEMPERATURE IN SEAWATER

90
80
70
Temperature [°C]

60
50
40
30
20
10
0
316L 317L 254 SMO SDSS

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Material Selection

 Destruction due to corrosion

 Material: 254 SMO
 Duty: Leaching solution
 Type: Pitting corrosion
 Cause: Increase of Cl- content from 10 g/l to 20 g/l
 Impeller state 25 days after Cl- content increase

 The effect of high Cl- content leads to two different mechanisms:

– Increase of corrosion due to Cl- leading to pitting corrosion

– Increase of corrosion due to H2SO4 leading to generalized corrosion

 SDSS / 254 SMO shall be restricted to medium Cl- content

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Material Selection

 Destruction due to corrosion

 Material: Hastelloy C 276
 Duty: Circulation of H2SO4 (concentrated solution)
 Type: Uniform corrosion
 Cause of corrosion: Abnormal temperature increase

 The effect of temperature leads to two different mechanisms:

– Increase of corrosion rate by Cl- leading to pitting corrosion

– Increase of corrosion rate by H2SO4 leading to generalized corrosion

 Hastelloy is not totally immune to corrosion for leaching applications

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Material Selection

 Iso-corrosion Chart for Hastelloy C 276 in H2SO4

Source: Sulphuric Acid on the Web

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Material Selection

 Iso-corrosion Chart in H2SO4 with Cl addition

Source: Sulphuric Acid on the Web

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Material Selection

 Heap Leaching – Material Selection

 Chloride content (Cl-)

– Congo: 316L is very successful no Cl-
– Peru: 316L is very successful few Cl-
– Chile: SDSS, 254 SMO, Hastelloy, Titanium > 5 g/l

 Selection guidelines for high Chloride content

– Cl- < 1 g/l: SS316L
– Cl- < 10 g/l: SDSS or 254 SMO
– Cl- > 10 g/l: Hastelloy C or Titanium

Note: Those selection guidelines shall be validated in line with operating conditions

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Material Selection

 Titanium Selection for Leaching Applications

 Casting: ASTM B367 Grade 3 (C.P.)

 Bar / Plate: ASTM B265 Grade 2 (C.P)

 Ti alloys: Grade 7 (Ti + Pd)

Grade 12 (Ti + Mo/Ni)

 Corrosion: Pitting / Crevice corrosion

 Mechanism: Passivation (oxide layer)

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Material Selection

 Titanium – Key Factors

 Temperature:
– All Ti Grade suitable for leaching applications with T < 50°C

 Treatment:
– Ti parts special treatment improve corrosion resistance

 Liquid composition:
– F³+ content improve Ti resistance to corrosion
– Cu & Na content has similar effect on Ti resistance to corrosion

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Material Selection

 Titanium – Grade Selection

 Gr 2, Gr 3, Gr 7, Gr 12 are all suitable for leaching operation
– Temperature max. < 50°C
– Cl- content up to 200 g/l and more
 Gr 7 has been developed for more stringent conditions
– High temperature applications (T> 50°C with low pH)
– Superior mechanical properties in extreme conditions (aeronautic)
– Pd content leads to high costs
 Gr 12 has been developed as alternative to Gr 7
– High temperature applications (T> 50°C with intermediate pH)
– Mechanical properties similar to Gr 3
– Intermediate cost

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Material Selection

 Titanium – Material Properties

Source: ASME II Part D

 Geometry and type of parts shall be taken into account

– Casting thickness
– Minimum tubes / plates thickness

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Material Selection

 Titanium – Case study

 Leaching Application (Chile)
– Horizontal pumps
– Cl content > 10.000 ppm
– Low / medium design pressure

Pump casing pressure design 25 bars or 50 bars in carbon steel

Gr 2 mechanical properties compatible with pressure requirements

Gr 2 may not be suitable for high tip speed

Gr 12 selection leads to higher costs (raw material)
Gr 3 is suitable for higher tip speed due to better mechanical properties

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Material Selection

 Titanium – Case study

 Leaching Applications (Chile)
– Vertical pump
– Cl content > 10.000 ppm
– Higher TDH
– Higher design pressure
Pump casing pressure 20 bars / 25 bars in carbon steel

Gr 2 standard plates are suitable to sustain design pressure

Special pattern necessary for casting to sustain design pressure

Gr 2 selection leads to thicker parts (oversizing)
Gr 12 selection leads to higher costs (raw material)
Gr 3 allow lighter parts due to better mechanical properties

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Material Selection

 Titanium – Conclusions
 Gr 2, Gr 3, Gr 7, Gr 12 are all suitable for leaching operation

 Gr 2 & Gr 3 are proven material selection for very high chloride content leaching
applications

 Gr 2 is standard material for bars and plates

 Gr 2 may be suitable for castings

 Gr 3 is preferable selection for castings

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