Engineering & Mining Journal

OCT 2018

Engineering and Mining Journal - Whether the market is copper, gold, nickel, iron ore, lead/zinc, PGM, diamonds or other commodities, E&MJ takes the lead in projecting trends, following development and reporting on the most efficient operating pr

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CORROSION OCTOBER 2018 • E&MJ 41 www.e-mj.com IMPACT PLUS users have the option to manage their own use of the product or work with a trained navigator with corrosion man- agement and consulting expertise. Naviga- tors help customers evaluate and compare their current asset management processes and advise them on future asset protection and corrosion management strategies. IMPACT PLUS offers a wide range of features, according to its developers, including: • An integrated platform for corrosion management professionals; • A common language and structure need- ed to ensure communication throughout all levels of an organization; • A straightforward way for companies to identify gaps in processes that could lead to the reduced lifecycle of assets due to mechanical, integrity or human error; • A Corrosion Management Maturity Mod- el that creates a roadmap of activities, investments, and best practices that lead to higher performance; • A Corrosion Management System Frame- work, which is an organizational struc- ture that enables effective corrosion mitigation while providing a positive return on investment; and • A reference library to manage know- ledge and information collected through all components of the portal. Going Digital Other companies are pursuing digital solu- tions for controlling corrosion, offering solu- tions largely drawn from technologies used in the petroleum/gas sector where corrosion can lead to disaster. For example, Accenture offers "digitally enabled" corrosion man- agement services and solutions that employ a three-pronged approach involving IoT, data visualization and advanced analytics to help companies achieve optimum asset value several different ways. This includes through increased certainty of zones/lines at risk; reduced scope and frequency of inspections; reduced cost and asset down- time due to inspections; increased asset life; and improved worker safety. Accord- ing to Accenture, these improvements can provide a 10-20% reduction in inspection costs, 10% or more increase in uptime and productivity, and improved asset integrity, increasing asset life by more than 20%. Services available through Accenture's program include: • Risk-based inspection methodology; • Asset integrity division readiness; • System and data integration enabled by its Data Analysis and Processing Tool (ADAPT); • Image and video analytics to detect sur- face defects and signs of corrosion; • Advanced analytics and deep learning using maintenance, design, operations, environmental and historical data; • Real-time, interactive equipment moni- toring by combining 3D modeling with its Active Network Model for Corrosion Management; and • Digital inspection technologies, includ- ing nanotechnology, ultrasound, laser spectrometry and optical non-destruc- tive testing. GE Inspection Technologies also said it is developing a family of corrosion man- agement and inspection tools, with initial focus on corrosion monitoring. Its first product in this area is a predictive corro- sion management application running on GE's Predix platform and utilizing RightTrax PM ultrasonic sensors installed to provide coating-thickness monitoring. This ap- proach, said GE, offers real-time thickness measurement and the ability to perform ad- vanced data analytics and visualizations. It will allow users to move from point-in-time to continuous thickness measurement, and thus enable customers to improve asset in- tegrity management while opening the door for innovative ways to utilize this data to optimize plant and process performance. Picking the Perfect Product A quick scan of the list of available corro- sion-preventative coating types illustrates the potential difficulty of selecting the right product for a specific problem. Common coatings, for example, include cross-linked or thermoset coatings, epoxy resins, polyure- thane resins, alkyd resins, inorganic resins and thermoplastics, among others — and each of these categories has certain bene- fits and application requirements. Specific products within each category may have their own subset of features, intended usage and targeted substrates. A few examples: Certain resin types such as polyvi- nylidene fluoride (PVDF) can be used in sprayable form or molded into various shapes and are now available in powder coatings that offer a new avenue for ac- cessing PVDF's ability to protect metal sub- strates used in mining and mineral process- ing from corrosion, abrasion and chemical attack. PVDF, according to suppliers, can succeed in applications where other types of materials such as fiberglass-reinforced plastic (FRP), elastomeric and urethane liners have prematurely failed. Major chem- ical companies such as Arkema and Sol- vay market their PVDF products under the brand names Kynar and Hylar, respectively. Another relatively new type of coating is chemically bonded phosphate ceramics or CBPCs. EonCoat is one of these — a spray-applied industrial coating that pre- vents rust on carbon steel. EonCoat "phos- phates" the steel to which it is applied, forming an amorphous magnesium iron phosphate layer. This layer, chemically bonded to the steel, is the first line of de- fense against corrosion. A white ceramic layer then forms over the alloy layer. This ceramic layer, the second line of defense, provides a reservoir of phosphate corrosion protection to continuously maintain the al- loy layer. The coating was developed and This diagram from NACE's IMPACT study illustrates the interaction between corrosion management systems (CMS) and other organizational management systems.

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