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By S. Koppalkar

ABSTRACT: The development and evolution of the gravity recoverable gold (GRG) test procedure at McGill University is reviewed in this paper. Since the late 1980s, the research group led by the late Professor André Robert Laplante at McGill University has undertaken fundamental studies and applied research of the Knelson concentrator to develop a sustainable method of estimating GRG. Historically, a concept of “free gold” was used, and it was de?ned as the gold that could be separated and recovered from gold ore by amalgamation. Due to health and safety hazards, the practical use of amalgamation has declined. Around 1994, a methodology using a 3-in Knelson concentrator to measure gravity recoverable gold was established at McGill University. As a result of more than 10 years of improvement and optimization, this technique has become a standard method of evaluating GRG for gold ores, gold plant streams and platinum group metals. By 2006, about 200 GRG tests were carried out at McGill University on ores from all over the world. Recently, a modi?ed version of the GRG test (a simpli?ed test) was developed to provide a quick and rough estimate of the GRG in a sample; this simpli?ed test has the advantage of reduced mass, processing time and cost. To recognize and honour the contributions made by the late Professor Laplante towards the establishment of a standard test procedure for assessing gravity recovery potential, the authors propose that the GRG test be named after Laplante.

Jan 1, 2010

By Todd Kennedy, Kurt Tischler

"This paper presents the field experience of Siemens with regard to Gearless Drives in the mining industry … We consider the elapsed production hours of Siemens Gearless Drives to be extensive enough to provide a reliable estimation of availability calculated on the basis of data representing repair time, downtime, and operating time. The users of Siemens Gearless Drives confirm an availability of more than 98% after exclusion of some major issues. The paper addresses all of these major issues of Siemens Gearless Drives, describes successfully applied corrective measures, explains the influences on the design of the drives, and lists the downtimes associated with each of these issues. INTRODUCTIONThe first Siemens Gearless Drive in mining began operation in 1980 and was installed on an iron ore grinding mill. As of September 2011, 40 Siemens Gearless Drives will have accumulated 136,000 machine days of operating time. According to pure rules of statistical analysis, this accumulated operating time may be too low to be used for a sample of field data to provide precise statistical values of availability, however we consider it large enough to provide indicative values of worthwhile consideration. This paper deduces the availability statistics of Siemens Gearless Drives in the mining industry from information received from end users and factors in all major issues that Siemens has experienced with our Gearless Mill drives. This paper does not consider Gearless Drives in other industries such as the cement industry. The cement plants, especially in the northern hemisphere, interrupt production for several months in the winter. This lengthy downtime is used to maintain the complete plant including the mills, their motors and their drives. The mining industry has more stringent and higher production requirements. In the mining industry, production must run 24 hours per day, 365 days a year."

Jan 1, 2012

By H. Al-Kazzaz

The 2-mm butt joints of ZE41A-T5 sand castings were laser welded using 1.6 mm EZ33A-T5 filler wire and a continuous wave Nd:YAG system at a power of 4 kW, surface defocusing and various welding speeds, Compared with the base metal, the fusion zone showed significant grain refinement due to high cooling rate, No grain coarsening was observed in the heat affected zone (HAZ). The porosity area percentage and total solidification crack length in the fusion zone (FZ) were reduced as the welding speed increased from 4 to 7 m/min, Fusion zone area, total penetration depth, and weld width decreased with increased welding speed, The hardness in the FZ was similar to or higher than the base metal after a natural aging of about one year, but there was a drop in the hardness of the HAZ, The HAZ width decreased with increasing the welding speed, Tensile test showed that a joint efficiency of approximately 75 ? 90 % was obtained.

Jan 1, 2005

By Tadeusz W. Wlodek

THE known phenomenon that a test-piece of ferro-magnetic steel is magnetic after it has been broken in tension indicates that, while it is being loaded, the steel acquires magnetic properties. In the present investigation of the influence of the stress on the magnetic flux, repeated pulsating stresses of increasing amplitude, varying from zero to the maximum tensile value, i.e., pull-pull loading, were employed. The specimens were prepared from two types of carbon steel and two of alloy steel. The magnitude of the magnetic flux was determined indirectly. The voltage and mode of variation of the electromotive force induced in a coil surrounding the stressed steel specimen were measured as an indication of the varying magnetic flux within the specimen. Curves representing the electromotive force induced by the varying magnetic flux show that as the tensile load increased so also the magnetic flux increased, with a corresponding increase in measured e.m.f. At a certain stress there is a sharp bend in the voltage curve (point Win the diagram, Figure 5); this critical stress corresponds very closely with the yield stress (0.2 per cent permanent strain). Beyond this point, slight increases in the stress produce large increases in the voltage. The wave form of the e.m.f. was registered on an oscillograph. Analysis of the curves so obtained demonstrated the necessity of continuing these experiments, in order to determine the type of induced wave form associated with various types and amplitudes of stresses. In these experiments, the shape of the stress wave was sinusoidal, although the shape of the induced e.m.f. was sinusoidal only up to a certain load and became more and more complex above this load.

Jan 1, 1944

By V. P. Mehrotra, D. W. Fuerstenau, A. -Z. M. Abouzeid

The use of pulverized coal for electric power generation results in the production of vast amounts of fly ash. One potential use for waste fly ash is the production of pellets for lightweight aggregates. This paper is concerned with the role of the physical and chemical characteristics of two different fly ashes in governing their agglomeration or pelletization behavior and their strength characteristics. In batch balling experiments, fly ash pellet growth was found to be extremely sensitive to the amount of moisture added. One ash (Mohave) exhibits marked pozzolanic activity whereas the other (Jim Bridger) does not. The pozzolanic activity has a very pronounced effect on pellet growth kinetics, moisture requirements, and the effect of various additives on growth kinetics. Slow drying under ambient conditions produces strong pellets from Mohave ash whereas Jim Bridger ash pellets lacking in pozzolanic activity are weak. Rapid drying at high temperatures results in weak pellets because water necessary for hardening is driven out of the pellet. Steam curing enhances pellet strength. Locked-cycle pelletizing experiments exhibit expected oscillation in pellet production rates and attendant fluctuations in pellet green strength.

Jan 1, 2004

By R. A. Parra, Fuentes, C. Godoy, L. E. Arias, C. A. Toro, M. Marin, E. Balladares, V. Parra, G. Reyes, S. N. Torres, D. Sbarbaro

In this paper, we report on the detection of spectral molecular emission of iron oxide (FeO) and copper oxide (CuxO) emitted by reactions occurring in a laboratory scale flash smelting process of pyrite (FeS2) as well as copper concentrate. The novelty of the technique is that, the molecular spectral emission sensing is achieved by using a low spectral resolution and low sensitive radiometer, enhanced with signal processing and matrix factorization techniques. The method was validated using a highly sensitive spectrometer, with a high spectral resolution; achieving a similar FeO spectral pattern as the one obtained after signal processing techniques over low resolution spectral signals. INTRODUCTION Visible-near infrared (VIS-NIR) spectroscopy is an optical contactless sensing technique commonly used to capture information about the emitted, absorbed, transmitted or scattered radiation in a physical or chemical process, with the presence or absence of an excitation light source such as a laser or a broad spectral band source. These techniques coupled with signal processing and machine learning algorithms, sometimes referred as chemometrics (Pisapia et al., 2018), can be found in processes such as: pharmaceutical (Kandpal et al., 2016); food (Coelho et al., 2016); combustion (Ballester & García-Armingol, 2010); siderurgy (Strakowski et al., 2014) industry, among others. In the extractive copper industry there are several technological developments using optical sensing techniques aimed to retrieve information about copper ore and concentrate mineralogical composition such as X-Ray Fluorescence, Qemscan® (Quantitative Evaluation of Minerals by Scanning Electron Microscopy) and X Ray Diffraction (XRD) analysis, however, because of the manual procedures to analyze the samples with these laboratory instrumentation, only discrete information during a daily based operation can be retrieved, making impossible for the operators to take decisions over the involved processes in real time. The aim of our research work presented here is to contribute with sensing and data analysis procedures based on VIS-NIR spectroscopy for the flash smelting process characterization, particularly in this paper, with the detection of FeO and CuxO molecular emissions in a laboratory scale setup.

Jan 1, 2019

By Gordon E. Forward

Sustainable development in the mining and metallurgical industrial sectors can be implemented by two distinct groups: 1. The managers and operators of existing facilities ? working with industrial processes and systems that have been operating for many years, in some cases several decades 2. Those who are engineering and building new facilities or upgrades of existing plants. The focus of this paper is to look at approaches and tools available to bring sustainable development thinking and action to these two distinct areas. The paper will discuss: 1. The concept of working with existing facilities and processes to minimize waste and maximize product from a regional raw material/resource consumption perspective using By-product Synergy. The BPS concept has been carried out in Texas (TXI-Chaparral?s STAR Example), in Calgary, Alberta with Suncor assistance, in Montreal, Quebec with Noranda as project leader and currently in Ontario with Dofasco as industry champion. Successful outcomes are presented. 2. A new approach to designing greenfield facilities or upgrades to existing plants using a sustainable development review process. Undertaking the review early in every project can institutionalize the concept of discussing and implementing waste elimination, design for environment, eco-efficiency, risk minimization and community awareness and involvement in the future capital stock. The review process has been developed as an excellent tool for measuring and reporting on a corporation?s sustainable development progress. Examples of how this approach has been adopted in the mining and metallurgical industry, and the resultant outcomes are given.

May 1, 2002

By A. L. Mular

Some specific cases of the collection of data from industrial grinding and classifying operations, and the development of models from the data so obtained, will be described. The problems encountered, the effort involved, and the value of the derived models in improving the plant efficiencies will be discussed and documented where possible.

Jan 1, 1971

By S. B. Ballantyne, D. R. Boyle

"Detailed studies have been conducted on the dispersion of uranium in stream waters and sediments around various types of mineralization and hitherto unexplained anomalous areas in the Okanagan Valley and Highland region of south-central British Columbia. These studies were part of the jointly funded and planned Federal-Provincial Uranium Reconnaissance Program of the Geological Survey of Canada and the British Columbia Ministry of Energy, Mines and Petroleum Resources. Statistical analysis of regional data indicates that U in stream waters and sediments varies considerably for different rock types, thus affecting data interpretation. In addition, the data demonstrate a poor correlation between U in stream waters and their associated sediments which can be largely accounted for by variations in climate and water and sediment composition. Regional trends in the distribution of U can be explained in terms of the above secondary factors as well as primary metallization phenomena.Significant correlations between U and F, and U and Mo can be explained by certain magmatic and mineral-forming processes. U shows little correlation with other base metals.The dispersion characteristics of U in the vicinity of Miocene "" basal type "" mineralization ; uraniferous pegmatite terranes, anomalous lineaments in granitic terranes and high-background volcano-sedimentary areas are discussed. Highly anomalous U concentrations in waters and sediments may not always be indicative of mineralization, and guidelines for interpretation require a sound knowledge of the geological and secondary processes operative in the area."

Jan 1, 1980

By J. Keough

During industrial electrowinning of copper, uneven growth can impact current efficiency, cause short-circuits in the cell and negatively impact the final quality of the metal product. Copper electrodeposits can be made smoother by incorporating a host of additives in the electrolyte but uneven copper growth may still occur due to variations in electrolyte composition throughout the cell-house. To quantify roughness, 3D images of the surface may be combined with scaling analysis to gain further insight into the deposit structure. Moreover, scaling analysis may offer a method to predict long-term deposit structure using short-term copper deposits. In this paper, the application of Atomic Force Microscopy (AFM) and scaling analysis are used to monitor copper growth and extract surface roughness characteristics. The cathode was a 304 stainless steel disc that was polished to a mirror finish. Copper was deposited onto this surface over a range of 10, 20 and 30 minutes from an acidic sulfate solution (40 g/L Cu) at 40oC from an electrolyte that contained or was free of guar. AFM images were acquired to obtain 3D topographical information on the samples and scaling analysis was performed to extract the root-mean-squared (rms) roughness, periodicity (grain size), aspect ratio of surface features and growth mechanism. INTRODUCTION During the process of copper electrowinning, the dissolved metal ions are reduced and thereby deposited onto a cathode substrate which is later recovered by stripping the metal from the cathode surface. Although this process is widely used in the industry, the conditions of the deposition procedure may cause the growth of the metal product to be uneven which can not only impact the current efficiency and final copper product quality but may also lead to plant interruptions through short-circuits if the anode and cathode make contact. To create more uniform copper deposits, a host of additives may be included in the electrolyte which may act as brighteners, leveling agents and inhibitors which may include guar gum, glue, thiourea or polysaccharides or polyacrylamides and their industrial use has changed over time (Moats, Luyima, & Cui, 2015). As such, the electrolyte composition is often complex and subtle variations in the solution matrix throughout the cell-house may impact the surface morphology of the final copper product. In an effort to quantify the roughness of copper samples, image analysis is often applied and may include Scanning Electron Microscopy (SEM) or Atomic Force Microscopy characterization. While both are appropriate, AFM offers 3-dimensional information which may be used to both qualitatively and quantitatively characterize the surface characteristics.

Jan 1, 2019

By A. Hussain

PAPER NOT SUBMITTED FOR PUBLICATION

Jan 1, 1987

By Jochen Petersen, Alison Lewis, Cledwyn Mangunda

Run-off and waste water streams high in dissolved metal content are generated in all mining operations. The metals pose a threat to life due to their persistent bio-accumulative toxic (PBT) characteristics. Hence, there is a need to treat mine waste water effectively. Lime precipitation is the technology of choice through which Fe, as the major metal species, is removed as Fe (III) oxyhydroxides with other metals co-precipitated and/or adsorbed. Sulphates are removed as gypsum or incorporated into the Fe phases. The resulting sludge has poor dewatering characteristics and is deposited in landfills, with an inherent risk of returning the Fe back into the water cycle through leaching. This study seeks to understand the mechanisms behind the formation of this sludge in terms of product quality. The relationship between process conditions and product characteristics has been investigated through exploring the effect of Fe (III) concentration on the precipitate product characteristics (particle size distribution (PSD), size, morphology and structure) and quality (in terms of filterability, settling ability, etc.) in a simplified system. Neutralisation of acidic synthetic aqueous Fe (III) sulphate streams containing 50, 400 and 800 mg/L Fe(III), respectively, was effected by mixing it in a continuous stirred tank reactor (CSTR) with dissolved calcium hydroxide for pH control at a residence time of 15 minutes. Precipitate samples analysed for morphology and PSD, using nanoSEM and Zetasizer respectively, showed a general decrease in PSD and zeta potential with increases in feed Fe (III) concentration. These results were used to infer the particle size enlargement mechanisms of Fe (III) oxyhydroxide precipitates under a given set of operating conditions. Preliminary product quality results indicate that a high concentration (800 mg/L) leads to the rapid formation of metastable precursors with poor product quality, whilst a low concentration (50 mg/L) leads to formation of thermodynamically more stable precipitates with good product quality. The approach demonstrates a potential route forward in terms of linking operating conditions to the attainment of desirable characteristics rather than specific precipitate phases which are difficult to identify.

Jan 1, 2016

By China University of Mining & Technology, Yuemin Zhao, Bo Zhang, Liang Dong, Zhenfu Luo, Chenlong Duan

"In China, approximately 65% of coal reserves are in the west region, where water shortage is a serious problem: high-efficiency dry coal beneficiation technology is desired. Using magnetic powder and fine coal as heavy medium, and using air as the fluidizing agent, a novel air dense medium fluidized bed separator is proposed for coal preparation. Coal can be efficiently separated according to density in the fluidized bed, where bed density is steady. The separator is highly reliable, the circulation quantity of heavy medium is low, and the gas distributor cannot be easily easily. The world’s first industrial modularized dry coal preparation plant was built by China University of Mining and Technology. Dry coal beneficiation technology was first used to produce low-ash coal. Results of industrial production show that the ash content of clean coal is 3.46%, the probable error E value is 0.055 g/cm3, and the organic efficiency is over 90%. The advantages of the modularized dry coal beneficiation system are the high separation accuracy, the simple process flow, the low operation cost, low energy consumption, and so on. This technology provides a new effective method for coal separation in acid region and coal tending to sliming.INTRODUCTIONCoal is the most important primary energy source in China, where coal output reached 3.68 billion tons in 2013 and represents approximately 68% of the primary energy consumption. Coal has made a great contribution to the development of the Chinese national economy, but it also brings serious environmental pollution. However, approximately 65% of coal reserves are in the arid west region in China where water shortages present a challenge for wet coal preparation technology. In addition, the abundant lignite resource, because it is easy to mud in the water, should not be treated with the wet separation method. Therefore, it is critical to develop highly efficient dry coal preparation technology to meet the demand in arid areas. Further, water resource shortages are a global problem, thus the development of efficient dry coal preparation technology in has potential application in other water-short countries like South Africa, Brazil, India and Turkey."

Jan 1, 2016

By R. Q. Honaker

A significant problem in ultrafine particle classification is the significant amount of submicron particle by-pass to the coarse particle stream. In classifying cyclones, submicron particle by-pass to the underflow stream can be reduced by decreasing water recovery. Past studies have shown that a reduction can be realized when the feed solids concentration is increased or the apex diameter is reduced. However, both adjustments tend to increase the particle size cut point and negatively affect classification efficiency due to the impact on slurry rheology. The addition of a viscosity modifier to the feed stream of a classifying cyclone improved the classification performance and decreased the particle size cut point over a range of feed solids concentrations. The detailed test program investigated the use of the modifier in conjunction with varying apex diameters to identify conditions that minimize ultrafine by-pass. With small apex sizes, roping conditions were readily eliminated by the addition of viscosity modifiers. The addition of the modifier had no deleterious effect on froth flotation performance, which commonly serves as a downstream separation process. The fundamental and practical benefits of viscosity modifiers in classification processes are discussed in this publication.

Jan 1, 2006

By Y. S. Sun, Northeastern University, W. B. Li, P. Gao, Z. Y. Zhang, J. W. Yu

"The boron-bearing iron concentrate was extracted from ludwigite ore by the process of magnetic-gravity separation. In order to fully utilize the refractory ore and meet the boron consumption of China, a novel process for separation of boron from iron in boron-bearing iron concentrate was proposed in this paper. In particular, laboratory scale experiments of improving boron reactivity were performed. Fine boron-bearing iron concentrate briquettes were reduced by bituminous coal completely at 1125 °C for 150 min. The effect of sodium carbonate, which was used as an additive in the roasting process, was investigated. The addition of sodium carbonate decreased the boron reactivity and facilitated the volatilization of boron. The influence of diverse cooling methods of the reduced samples on the boron reactivity was studied. The results indicated that boron reactivity could reach up to 80.76% when the reduced samples were cooled by rapid water quenching. In addition, the magnetic material containing 92.71 % Fe with a recovery of 95.11 % and boron-rich non-magnetic material containing 14.51% B2O3 with a recovery 88.85% could be obtained by low-intensity magnetic separation. The magnetic material and boron-rich non-magnetic material were good raw materials for steel-making and borax production, respectively.INTRODUCTION Ludwigite ore is abundant in Liaoning province of China, with 28.43 Mt B2O3 accounting for 57% of the boron resources of the country (Liu et al., 2006). However, it has not yet been utilized on an industrial scale due to its complex mineralogy and fine mineral dissemination (Wang, Wang, Ding, Ma & Xue, 2012). At present, boron-bearing iron concentrate and boron concentrate can be obtained from ludwigite ore using magnetic-gravity separation. The boron concentrate contains B2O3 12%~16%, which can be used as a high-quality raw material for the boron chemical industry after activated roasting, but the B2O3 content in the iron concentrate reaches up to 4%~6%. In order to further separate boron and iron from boron-bearing iron concentrate, a blast furnace and a solid pre-reduction followed by electric arc furnace melting have been proposed (Liu, Cui & Zhang, 1998; Wang et al., 2012). However, both of these two current routes face the same crucial problem that molten boron-rich slag has to be cooled slowly to obtain the alkali-dissolution activity of boron, which affects the yield of boron resource."

Jan 1, 2016

By Stanley W. Holmes

"The discovery of extensive uranium mineralization on the Pronto property in April 1953 initiated a program of staking, exploration, and development unparalleled in Canadian mining history. Within twelve months of the discovery hole, sufficient ore had been blocked out to merit a 55-million-dollar contract with Eldorado Mining & Refining Co. On October 15, 1955, two years and four months after discovery, Pronto went into production with a mill rated at 1,000 to 1,500 tons per day. The property is on the southern edge of the Algoma uranium district, 10 miles east of the town of Blind River and close to the Canadian Pacific Railway and Highway 17. Docking facilities for Great Lakes steamers are avail-able at Spragge, 4 miles to the east.The data and conclusions presented in this paper are based on field studies, drill hole information, and underground development. The ideas of ore genesis are those of the writer, and will undoubtedly be modified as more detailed studies and research are carried out. Because of security regulations, information pertaining to grade and tonnage will not be discussed.GeologyThe general geology of the Algoma basin has been outlined in a pre-ceding paper (Joubin and James). The description below is concerned essentially with the rocks most closely associated with the Pronto deposit. They may be grouped in three structural and lithological units: (1) the pre-Huronian basement, (2) the Mississagi formation, the lowest member of the Huronian sediments lying unconformably on the basement, and (3) a series of basic intrusives cutting (I) and (2). Most of the uranium mineralization occurs in a quartz-pebble conglomerate forming the basal member of the Mississagi quartzite."

Jan 1, 1949

By K. Ilankoon, I. M. Saman, S. J. Neethling

In heap leaching the transport of the acid from the drippers to the surface of the ore particles is a major factor in the overall performance of a heap. This flow behaviour is complex as the flow is unsaturated and occurs along a tortuous set of inter-particle channels and connections. The particle properties such as size, shape and porosity are very important when modelling the liquid holdup and flow within heaps, since the dominant mechanisms at work are quite different. This paper investigates the effect of these particle properties experimentally on heap flow behaviour using a 1-D column leaching system consisting of non-porous glass beads with a system of actual ore particles. The similarities and differences between the two systems on flow behaviour are described using an inter-particle flow model. In addition, the applicability of positron emission particle tracking (PEPT) for laboratory column leaching will be detailed to calculate hydrodynamic dispersion in packed beds compared to more conventional residence time distribution (RTD) tests and also to obtain the time averaged rivulet flow paths through the particles of the bed for the better understanding of heap hydrodynamics.

Jan 1, 2014

By \/eena Sahajwalla, Alexander Blagus

This paper reports the effect of using High Density Poly-Ethylene (HDPE)/coke blends on the reduction behaviour of Mn3O4 to MnO at 1000°C. The results suggest that CH4 release increases with increasing HDPE addition. The results show that the rapid release of methane, over only the initial five minutes, limited the interaction of Mn3O4/MnO with CH4. With the devolatilisation of HDPE there was increased porosity in samples containing HDPE, assumed to be the major factor in differences of reduction rates.

Jan 1, 2011

By A. R. Farkoosh, J-P. Fortin, M. Pekguleryuz, S. Bagherpour

"Titanium aluminides are structural intermetallics which offer an attractive combination of high temperature strength and light weight. For such properties, these intermetallic alloys have become front-runners in replacing nickel-based superalloys used for several high temperature applications. These alloys are produced from metallic titanium, aluminum and master alloys involving an expensive and difficult process. A low cost alternative to current industrial production method is the new modified aluminothermic process which directly reduces titanium oxide (TiO2) to titanium aluminides. Nevertheless, this process has itself significant challenges in achieving alloys free of oxide inclusions; the close densities of the slag and the titanium aluminides makes slag/molten metal separation a challenging task. Usually, the alloy produced requires a second refining step. In this study, thermodynamic calculations based on CALPHAD method were performed to determine the solidification path and an attempt has been made to develop a criterion to increase the density deference between the slag and the alloy by alloying with appropriate elements. Furthermore, scanning electron microscopy (SEM) and x-ray diffraction (XRD) techniques were utilized to examine the microstructure and phase selection of three Ti-Al alloys produced by the aluminothermic reaction, including the as-cast, refined in a controlled atmosphere and inert-gas-refined alloys. The composition range of the alloys studied was restricted to the a2-Ti3Al + ?-TiAl phase field (Ti-30Al) in the binary Ti-Al phase diagram leading to a lamellar structure with different complex intermetallics as shown in Figure 1.INTRODUCTIONTiAl based alloys are promising structural materials for high temperature aerospace and automotive applications. This is due to some attractive properties such as low density, high specific strength, high specific stiffness and high temperature strength retention (Wen-bin, Xue-wen, Hong-fei, & Yong-feng, 2011). These alloys have become leading candidates to replace Ni-based super alloys in gas turbine engines. Replacement of Ni-based super alloy parts with titanium aluminides is expected to reduce the structural weight of high performance gas turbine engines by as much as 20–30% (Kothari, Radhakrishnan, Sudarshan, & Wereley, 2012)."

Jan 1, 2016

By Afshin Sadri, Wai Lai Ying, Brycklin Wilson, Zoe Coull

"Although there have been great steps forward to integrate corrosion engineering into operations, there is still an underlying tendency for maintenance tasks to be performed in a reactive manner. This is especially true when strategies focus on lagging indicators such as visual inspections, RCA (root-cause analysis), and FMECA (failure mode, effects and criticality analysis). This trend to “reactive maintenance” can be avoided by utilizing more inspection and monitoring methods to identify leading indicators of failures. Prevention is generally less costly than repairs; moreover, when paired with appropriate monitoring techniques, intervention of corrosion protection can be more effectively timed and based on more accurate data. Hatch asset reliability studies show nearly 80% of defects are introduced through operations and maintenance. Therefore, proactive corrosion management can provide the necessary feedback to optimize operations and maintenance strategies preventing costly corrosion losses. Understanding corrosion risks gives a clear picture of the benefits of a proactive approach to asset performance. Monitoring techniques (Non-Destructive Testing, field testing, sampling, etc.) by nature are a more effective means of improving maintenance efforts and preventing corrosion losses than other methods (RCA, FMECA). This paper will outline the importance of proactive corrosion management and demonstrate its benefits through industry examples.INTRODUCTION Over the past few decades, with the growth of technology and awareness of sustainable development many studies have shown the benefits of a proactive approach to maintenance strategies. However, in practice there is still an underlying tendency for maintenance tasks to be performed in a “reactive manner”. This is especially true when strategies focus on lagging indicators such as visual inspections, RCA (root-cause analysis), and FMECA (failure mode, effects and criticality analysis). This trend to “reactive maintenance” can be avoided by utilizing more inspection and monitoring methods to identify defects and leading indicators to failures."

Jan 1, 2017