IGS HVTS cladding has been successfully used over the past decade to provide protection for heat recovery boilers and heat recovery steam generators (HRSG) in the mining and mineral processing industries. Our cladding successfully minimizes failures and repairs caused by corrosion-erosion metal wastage of heat recovery boilers and ducts in zinc and copper smelters.
IGS High Velocity Thermal Sprayed (HVTS) cladding is ideal for protecting against the high-temperature corrosion and erosion environment in the Mining & Mineral processing industry. We have developed our IGS 5HVTS alloy cladding for protection in combustion environments with aggressive sulfidation conditions up to 1800°F (980°C). It is highly protective against under deposit corrosion when Sulfur together with Sodium, Potassium and Vanadium oxides form low melting temperature eutectic pyro-salts. The high Chromium alloy, together with unique structurally densifying chemistry, provides a practically impermeable inert alloy cladding, with high bond strength. The material also has good erosion resistance due to effective hard-phase integration in a ductile binder.
IGS HVTS cladding eliminates metal wastage, limiting production losses due to unplanned downtime. The composite system is also effective in inhibiting heavy slag adhesion.
IGS is the pioneer in the use of Thermal Spray claddings in the Mining & Mineral Processing Industry. We have completed dozens of applications for heat recovery steam generators over the past decade. We use our knowledge and experience to successfully support HRSG users with proven solutions for their most critical assets. IGS has considerable experience applying High Velocity Thermal Spray and Weld Overlay surface protection solutions to copper and zinc smelter waste heat recovery boilers. Our principal services have included fireside protection with corrosion-erosion resistant proprietary high alloy, high temperature, metal coatings on HRSG and converter furnace tubes, off-gas ducting, and automated cladding on cooler plates.
Given the increase in the smelting intensity planned for PGM furnaces at higher power, water-cooled plate coolers are installed in the sidewalls in the slag zone. Transition coolers in converter furnaces freeze any slag splashes and thus prevent slag leaks. IGS utilizes a synergic pulsed GMAW process in semi-automatic or automatic modes. The main modes of metal transfer to the base metal, in order of increasing current density, globular transfer, spray transfer, and rotating transfer. The strong magnetic field from rapid high current pulsing initiates rotary spray transfer with a droplet size much less than the electrode diameter. The higher peak but lower background current results in less heat, less distortion and less dilution, providing a reduced heat-affected zone with better cladding chemistry.
Because automated cladding is often suited for a part, but not all, of our customers’ wastage problems, IGS provides turnkey High Velocity Thermal Spray, automated and manual weld overlay, mechanical services and project management. IGS maintains an “R” stamp through the NBIC. All work we undertake complies strictly with ASME Sections VIII and IX, the IGS Quality Control Plan, and customer-specific requirements.
Many Mining industry facilities are focused on the reduction of SO2 emissions. A specific drive to reduce these emissions has led to the building of Acid Converter Plants. The process conditions in these furnaces contribute to wall corrosion with the generation of both Sulphur and other corrosive Halide salt species. The presence of H2S may lead to cracking, especially in the roof and freeboard panel sections. These are typically protected by monolithic refractory, but the remainder of the tubes are exposed to the high-temperature conditions inside the furnace.
IGS HVTS is a strong protection system that may protect tubes from acid dew point corrosion, high-temperature sulfidation, oxidation and erosion, caused by the sulfur and water environment. HVTS cladding systems act as a barrier that prevents the gaseous sulfur and chloride components from contacting the base metal, thereby preventing high-temperature corrosion.
Over the past decade, we have leveraged our experience and knowledge to develop unique materials and methods. We did it to provide reliable and predictable protective barriers in the most challenging mining and mineral processing environments. We have learned that: