Corrosion resistant fluidic devices for hydrometallurgical systems

Abstract

A hydrometallurgical system includes a feed inlet configured to receive a feed material containing a bound target metal, a leaching agent inlet configured to receive a leaching agent, a product outlet configured to discharge a slurry containing an extracted target metal, and one or more fluidic devices coupled between the feed inlet, the leaching agent inlet, and the product outlet to define a leaching flow path along which the leaching agent contacts the feed material to form a slurry product, wherein a first of the one or more fluidic devices includes an interior defined by a contact surface, wherein the contact surface includes a corrosion resistant coating containing chromium oxide and barium glass.

Description

2942-06001 CORROSION RESISTANT FLUIDIC DEVICES FOR HYDROMETALLURGICAL SYSTEMS CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims benefit of U.S. provisional patent application No. 63 / 643,082 filed May 6, 2024, entitled “Corrosion Resistant Fluidic Vessels for Hydrometallurgical Systems”, which is incorporated herein in its entirety for all purposes. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable. BACKGROUND

[0003] Metals play a vital role in modern technologies. Examples of useful metals include copper, nickel, cobalt, gold, silver, iron, and rare earth elements. These metals contribute significantly to various components such as structural materials, instruments, high-strength magnets, batteries, phosphors, and catalysts. These components are used in various industrial applications, including construction, power generation, health care, transportation, refining, and consumer electronics, due to their physical, chemical, and mechanical properties. Metals and metal compounds are often found in ores, concentrates, industrial by-products, and recycled materials from which they may be extracted or recovered using extractive techniques. Interest and research into the recovery of metals from natural deposits, end-of-life products, and secondary sources, such as hydrometallurgical plants, produced water, and industrial effluents from battery recycling plants and mining operations, have increased due to their critical role. For example, hydrometallurgy, a field within extractive metallurgy, includes techniques that use aqueous solutions to extract a wide range of metals from various sources, including ores, concentrates, industrial by-products, and recycled materials. SUMMARY OF THE DISCLOSURE

[0004] An embodiment of a hydrometallurgical system comprises a feed inlet configured to receive a feed material containing a bound target metal, a leaching agent inlet configured to receive a leaching agent, a product outlet configured to discharge a slurry containing an extracted target metal, and one or more fluidic devices coupled2942-06001 between the feed inlet, the leaching agent inlet, and the product outlet to define a leaching flow path along which the leaching agent contacts the feed material to form a slurry product, wherein a first of the one or more fluidic devices comprises an interior defined by a contact surface, wherein the contact surface comprises a corrosion resistant coating containing chromium oxide and barium glass. In some embodiments, a content of the chromium oxide exceeds a content of the barium glass. In some embodiments, a ratio of chromium oxide to barium glass is equal to or greater than 60:40. In certain embodiments, a ratio of chromium oxide to barium glass ranges from 60:40 to 98:20. In some embodiments, the barium glass comprises alkali. In some embodiments, a thickness of the corrosion resistant coating is between 0.006 inches and 0.011 inches, or less than 0.1 inches. In certain embodiments, a coefficient of thermal expansion of the contact surface is within 2% to 5% of a thermal coefficient of expansion of the corrosion resistant coating. In certain embodiments, the corrosion resistant coating is further configured to prevent adhesive and abrasive wear of the contact surface, and lower a coefficient of friction between the contact surface and other components of the system. An embodiment of an acidic system comprises one or more process vessels, a feed tank coupled to the one or more process vessels, a scrubber unit coupled to the one or more process vessels, and the system of claim 1, wherein the acidic system is configured to handle an aqueous solution having a pH value of less than 7. In some embodiments, the corrosion resistant coating comprises a bond coat and a separate topcoat that varies in composition from the bond coat. In some embodiments, the bond coat comprises tungsten carbide. In certain embodiments, a coefficient of thermal expansion of the bond coat is within 2% to 5% of a thermal coefficient of expansion of the topcoat.

[0005] An embodiment of a method of applying a corrosion resistant coating to a fluidic device comprises mounting the fluidic device onto a fixture and loading an applicator with a corrosion resistant coating material comprising chromium oxide and barium glass, (b) plotting a spray course based on a geometry of the fluidic device and adjusting a rate, speed and distance of an applicator to predefined values based on the spray course, (c) loading the corrosion resistant coating material onto a feeder and setting control parameters of the applicator based on a desired coating thickness, and (d) dispensing the corrosion resistant coating material onto the fluidic device. In certain embodiments, a content of the chromium oxide exceeds a content of the barium glass. In some embodiments, a ratio of chromium oxide to barium glass of the2942-06001 corrosion resistant coating material ranges from 60:40 to 98:20. In some embodiments, the barium glass is alkali. In certain embodiments, the corrosion resistant coating is dispensed as a plasma onto the fluidic device. In certain embodiments, the corrosion resistant coating is configured to resist corrosion in up to 98% acidic solution, at a temperature of 300oC or greater, at a pressure of up to 725 pounds per square inch or greater, for a period of three years, at least three years, or greater than three years. In some embodiments, a coefficient of thermal expansion of a contact surface of the fluidic device is within 2% and 5% of a thermal coefficient of expansion of the corrosion resistant coating.

[0006] An embodiment of a fluidic device for a hydrometallurgical system comprises a body defining a surface, and a corrosion resistant coating formed on the surface of the body, the corrosion resistant coating comprising chromium oxide and barium glass.

[0007] Embodiments described herein comprise a combination of features and characteristics intended to address various shortcomings associated with certain prior devices, systems, and methods. The foregoing has outlined rather broadly the features and technical characteristics of the disclosed embodiments in order that the detailed description that follows may be better understood. The various characteristics and features described above, as well as others, will be readily apparent to those skilled in the art upon reading the following detailed description, and by referring to the accompanying drawings. It should be appreciated that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes as the disclosed embodiments. It should also be realized that such equivalent constructions do not depart from the spirit and scope of the principles disclosed herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] For a detailed description of various exemplary embodiments, reference will now be made to the accompanying drawings in which:

[0009] FIG. 1 is a schematic diagram of a hydrometallurgical system according to some embodiments;

[0010] FIG.2 is a schematic diagram of an exemplary fluidic device in accordance with principles disclosed herein;2942-06001

[0011] FIG.3 is a schematic diagram of a cross sectional view of the fluidic device of figure 2 in accordance with principles disclosed herein;

[0012] FIG. 4 is a cross sectional view of an exemplary flange of the fluidic device of figure 2 in accordance with principles disclosed herein;

[0013] FIG.5 is an image of an exemplary acid injection ball valve with coating failure according to some embodiments;

[0014] FIG.6 is a schematic diagram of another exemplary fluidic device in accordance with principles disclosed herein

[0015] FIG. 7 is a schematic representation of a coated surface in accordance with principles disclosed herein;

[0016] FIG.8 is an image of a coated surface in accordance with principles disclosed herein;

[0017] FIG. 9 is a block diagram of a coating system in accordance with principles disclosed herein;

[0018] FIG.10 is a flowchart of a method of preparing the corrosion resistant coating material in accordance with principles disclosed herein;

[0019] FIG.11 is a flowchart of a method of applying the corrosion resistant coating to a fluidic device in accordance with principles disclosed herein;

[0020] FIG. 12 is a flowchart of another method of applying the corrosion resistant coating to a fluidic device in accordance with principles disclosed herein;

[0021] FIGS.13A and 13B are exemplary images illustrating the result of a corrosion test using the composition and methods described in accordance with principles disclosed herein; and

[0022] FIGS. 14A and 14B are graphical representations of x-ray diffraction from the corrosion tests illustrated in FIGS.10a and 10b in accordance with principles disclosed herein; and

[0023] FIG.15 is a block diagram of a computer system in accordance with principles disclosed herein. DETAILED DESCRIPTION

[0024] The following discussion is directed to various embodiments. However, one skilled in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure,2942-06001 including the claims, is limited to that embodiment. The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.

[0025] In the following discussion and in the claims, the terms "including" and "comprising" are used in an open-ended fashion, and thus should be interpreted to mean "including, but not limited to…" Also, the term "couple" or "couples" is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection as accomplished via other devices, components, and connections. In addition, as used herein, the terms "axial" and "axially" generally mean along or parallel to a central axis (e.g., central axis of a body or a port), while the terms "radial" and "radially" generally mean perpendicular to the central axis. For instance, an axial distance refers to a distance measured along or parallel to the central axis, and a radial distance means a distance measured perpendicular to the central axis. Any reference to up or down in the description and the claims is made for purposes of clarity, with "up", "upper", "upwardly", "uphole", or "upstream" meaning toward the surface of the wellbore and with "down", "lower", "downwardly", "downhole", or "downstream" meaning toward the terminal end of the wellbore, regardless of the wellbore orientation.

[0026] As described above, hydrometallurgy is a field within extractive metallurgy that involves the use of aqueous solutions to extract metals from ores (e.g., ore bodies), concentrates, or recycled materials. Generally, ores are minerals (crystalline solids having a specific crystal structure that occurs naturally in pure form) having a significant concentration of a specific element such as a metal. Leaching is a common method within hydrometallurgy in which a metal of interest is at least partially dissolved as a solute from an initial feed material (e.g., in the form of an ore matrix) using a corresponding solvent in the form of a leaching agent or “lixiviant” such as an aqueous lixiviant. This is typically accomplished by exposing the feed material to a suitable leaching agent such as an acid, a base, and / or complexing agents under controlled conditions (e.g., temperature, pressure, and / or potential of Hydrogen (pH) level). The leaching agent may selectively dissolve the target metal ions present in the feed material while leaving the waste product or undesirable minerals unaffected. In some applications, hydrometallurgical processes may be performed continuously with a constant or continuous feed of the feed material. In addition, hydrometallurgy offers2942-06001 several advantages over alternative metallurgical methods including, for example, lower energy consumption, reduced environmental impact, and the ability to process complex and low-grade ores.

[0027] As used herein, the term “hydrometallurgical system” refers to a fluid system comprising a leaching agent and one or more fluidic devices for handling the leaching agent whereby the leaching agent may contact an initial feed material received by the hydrometallurgical system to form a working fluid or slurry (e.g., ore or concentrate suspended in a liquid medium) from which one or more target metals of the feed material may be extracted. The fluidic devices of the hydrometallurgical system may comprise one or more surfaces that contact the leaching agent and / or the slurry (or another fluid) containing the leaching agent to direct the leaching agent / slurry along one or more predefined fluid flow paths of the hydrometallurgical system. The fluidic devices of the hydrometallurgical system may heat, cool, mix, agitate, and / or perform other operations on the leaching agent, slurry, and / or other fluids of the hydrometallurgical system.

[0028] Hydrometallurgical systems typically include pressure vessels, feed tanks, valving (e.g., gate valves, ball valves, control valves), fluid conduits (e.g., pipes, spools, pipelines), scrubber units, and the fluids directed therethrough including the leaching agent and the slurry formed from the leaching agent and an initial feed material. As described above, in hydrometallurgical systems the leaching agent is contacted with the feed material (forming the resulting slurry) and the target metals are extracted therefrom under predefined controlled conditions facilitated by the hydrometallurgical system and the one or more fluidic devices thereof.

[0029] In some embodiments, the controlled conditions of the hydrometallurgical system under which the target metals are extracted may depart in one or more ways from ambient conditions (e.g., standard temperature and pressure). For example, the controlled conditions to which the slurry formed from the leaching agent and the feed material is exposed may be at a pressure and / or a temperature that departs significantly from ambient conditions. Particularly, the pressure and / or temperature of the controlled conditions may be significantly elevated relative to ambient conditions. Thus, in some embodiments, one of the fluidic devices of the hydrometallurgical system is a pressure vessel referred to as an “autoclave” or “autoclave vessel” configured to agitate a working fluid (e.g., the slurry of the hydrometallurgical system) as the working fluid is maintained in an extraction state under one or more predefined non-ambient conditions (conditions that depart from ambient conditions) such as an elevated (e.g., above ambient)2942-06001 temperature and / or pressure to facilitate extraction of one or more target metals. For example, the autoclave may include one or more passive agitating elements (e.g., internal baffles) and / or active agitating elements (e.g., mechanical agitators) for agitating, mixing, or perturbing the working fluid of the autoclave.

[0030] In certain applications, (e.g., extraction of nickel and cobalt from laterite ores), hydrometallurgical systems may employ autoclaves to implement high pressure acid leaching (HPAL) techniques to extract one or more target metals (e.g., nickel and cobalt) from feed material such as ores including laterite ores. In a typical HPAL process, the process begins with mining the ore, which is then crushed to a fine powder and mixed with a liquid forming a feed material. The feed material is fed into a horizontal autoclave vessel that may have several stages or compartments. Large quantities of a leaching agent, which may be in the form of an aqueous solution (e.g., sulfuric acid or cyanide solutions), is fed through corrosion resistant metal-seated isolation valves into each compartment to initiate the leaching reaction. The slurry formed from the leaching reaction may flow over the baffle walls of each compartment and is eventually discharged to a flash unit or vessel of the hydrometallurgical system configured to return (or at least assist in returning) the slurry from the extraction state to the ambient state whereby the slurry is no longer maintained under the one or more non-ambient conditions. For example, the flash vessel may release pressure applied to the slurry when in the extraction state.

[0031] Often, the most significant challenge for the equipment (e.g., fluidic devices) used in hydrometallurgical processes are corrosion and erosion resulting from contact (e.g., continuous contact) with leaching agents maintained, in at least some applications, under non-ambient conditions such as elevated temperatures and pressures. For instance, in some applications, the slurry that travels through the equipment is highly acidic which may cause wear over time. Thus, to protect the equipment from corrosion and erosion, the inside of equipment used in hydrometallurgical processes are made from corrosion resistant materials or a corrosion resistant lining or coating applied to the contact surface of the equipment.

[0032] Conventionally, titanium equipment has been used in hydrometallurgical systems because of the corrosion resistance they provide in high temperature, high pressure, and / or acidic processes. However, in recent times, corrosive conditions associated with temperatures, pH levels, and pressures have become more severe in HPAL processes such that neither titanium nor tantalum, nor a combination of both metals coated with,2942-06001 e.g., titanium oxide, can effectively resist corrosion resulting from contact with leaching agents under such extreme conditions. For example, HPAL processes may utilize temperatures up to or exceeding 250 degrees Celsius (oC), pressures up to or exceeding 725 pounds per square inch (PSI), and leaching agents comprising concentrated acids such as concentrated sulfuric acid (e.g., 98% sulfuric acid) to extract one or more target metals from a feed material. At these conditions, contact surfaces of a titanium fluidic devices may corrode at an undesirably high corrosion rate whereby a leak or other operational issue in the corroded fluidic device may result. For instance, leakage in a corroded fluidic device of a hydrometallurgical system may lead to fluid loss, decreased system performance, contamination, safety risks, system downtime, and / or component damage resulting in an overall decline in system performance or even a shutdown of the hydrometallurgical system in order to address the issue.

[0033] In other applications, chromium based coatings have also been used. However, chromium based coatings can create pores, which may compromise the effectiveness of the coating as a barrier against corrosion or wear. For example, these pores may allow corrosive agents or contaminants to penetrate the coating and reach the contact surface, leading to degradation over time. Additionally, chromium-based coatings typically must be applied using a plasma arc spray process due to difficulties inherent in adhering chromium-based coatings to certain contact surfaces, thereby increasing the costs associated with chromium-based coatings which limit the range of their technical applications.

[0034] Accordingly, embodiments of hydrometallurgical systems are described herein that include a feed inlet configured to receive a feed material containing a bound target metal, a leaching agent inlet configured to receive a leaching agent, a product outlet configured to discharge a slurry containing an extracted target metal, and one or more fluidic devices coupled between the feed inlet, the leaching agent inlet, and the product outlet to define a leaching flow path along which the leaching agent contacts the feed material to form the slurry product. In an embodiment, the one or more fluidic devices comprises an interior defined by a contact surface, where the contact surface comprises a corrosion resistant coating configured to resist corrosion. In some embodiments, the corrosion resistant coating of the fluidic device of the hydrometallurgical system comprises a powdered composite of at least chromium oxide and barium glass in which the chromium oxide content exceeds the barium glass content. In some embodiments, the ratio (by mass or volume) of chromium oxide to barium glass ranges from 60:40 to2942-06001 98:20, and the thickness of the corrosion resistant coating is between 0.006 inch and 0.011 inch, or less than 0.1 inch. The corrosion resistant fluidic device disclosed herein is configured to resist corrosion in up to 98% acidic solution, at a temperature of 300oC or greater, at a pressure of up to 725 psi or greater, for a period of three years, at least three years, or greater than 30 days. Embodiments of systems disclosed herein, provide a coefficient of thermal expansion of the contact surface that is within 2% to 5% of a thermal coefficient of expansion of the corrosion resistant coating.

[0035] As will be discussed further herein, embodiments of corrosion resistant fluidic devices are discussed herein in the context of acidic systems in the form of a hydrometallurgical system. However, it may be understood that embodiments of corrosion resistant fluidic devices disclosed herein may extend beyond fluidic devices and hydrometallurgical systems.

[0036] Referring now to FIG. 1, an embodiment of a fluidic system in the form of hydrometallurgical system 10 is shown. Hydrometallurgical system 10 is generally used to extract one or more target metals from a solid feed material (e.g., ore) by contacting the solid feed material (e.g., in the form of fines suspended in a liquid as part of a slurry). The exact configuration of hydrometallurgical system 10 may vary depending on factors such as the type of feed material being processed, and the desired metals to be extracted. In this exemplary embodiment, hydrometallurgical system 10 generally includes an autoclave 20, a feed inlet 11 configured to receive a feed material of hydrometallurgical system 10 containing one or more bound target metals, a high pressure (HP) heater 12, a plurality of feed pumps 13, a heating medium (e.g., steam) inlet 14, a heating medium tank 15, a quench vessel 16, a flash vessel 17, a leaching agent inlet 18 configured to receive a leaching agent of hydrometallurgical system 10, a seal supply 19, and a discharge outlet 30 configured to discharge a product (e.g., a slurry) containing an extracted target metal that is no longer bound to the original feed material. Hydrometallurgical system 10 also includes a plurality of isolation valves 32, control valves 34, pressure release valves (PRVs) 36, and / or other valving used to regulate the flow, pressure, temperature, and level of feed material and slurry across one or more fluid conduits 38 (e.g., pipes, spools, manifolds) of hydrometallurgical system 10 connected between the various valves and other components thereof. The specific type, configuration, and position of the valves may vary depending on factors such as the flow rate, pressure, temperature, and fluid characteristics of system 10. Additionally, hydrometallurgical system 10 may also2942-06001 include other auxiliary equipment such as agitators, scrubber units, blowback vessels, chokes, etc. that are necessary for supporting and facilitating the recovery of metals.

[0037] As described above, feed inlet 11 receive the feed material that is acted upon by hydrometallurgical system to produce one or more extracted target metals. In some embodiments, the feed material received at feed inlet 11 comprises a slurry containing solid feed material suspended in a liquid carrier, where the solid feed material comprises one or more target metals bound to the solid feed material. Examples of some ores or other materials that could be used as feed material includes magmatic sulfide deposits, where the principal ore mineral is pentlandite (Ni,Fe)9S8, and laterites, where the principal ore minerals are nickeliferous limonite (Fe,Ni)O(OH) and garnierite (a hydrous nickel silicate). In some embodiments, the feed material received at feed inlet 11 is in the form of solid bodies such as ore bodies and hydrometallurgical system 10 may include additional equipment for breaking these solid bodies down into finer particles and for mixing these finer particles with a liquid to form the feed material that is eventually communicated to the autoclave 20.

[0038] In this exemplary embodiment, HP Heater 12 of hydrometallurgical system 10 is coupled between feed inlet 11 and feed pumps 13. The HP heater 12 is configured to preheat the feed material received by feed inlet 11 to a target temperature before it enters autoclave 20. Preheating may be accomplished by steam injection or any other suitable means. Preheating the feed material reduces the amount of energy required to reach the target temperature for the subsequent chemical reactions in autoclave 20. An isolation valve 32 may be coupled to HP heater 12. The isolation valve 32 coupled to HP heater 12 may provide a means to isolate and drain or depressurize HP heater 12 in case of an emergency or during shutdown procedures, allow for cleaning and maintenance of HP heater 12, and periodic sampling of the feed material circulating through HP heater 12.

[0039] Hydrometallurgy system 10 may include a plurality of feed pumps 13 coupled between HP heater 12 and autoclave vessel 20 as shown in FIG.1. Feed pumps 13 is configured to transport feed material from a feed tank (not shown) through product inlets 23 of autoclave 20, and thereby maintain continuous supply of feed material to autoclave vessel 20. Feed pumps 13 may also be configured to maintain fluid pressure in the system, regulate flow rate of the feed material, and facilitate mixing of the feed material with the aqueous solution. Feed pumps 13 may include positive displacement pumps, centrifugal pumps, vertical pumps, horizontal pumps, etc. Feed2942-06001 pumps 13 selection may depend on factors such as the characteristics of the feed material being pumped, flow rate, pressure requirements, viscosity, solids content, and operating conditions of the system. In this embodiment, a plurality of isolation valves 32 are coupled between HP heater 12 and feed pumps 13. For example, the plurality of isolation valves 32 coupled between HP heater 12 and feed pumps 13 may allow operators adjust the flow rate of the feed material as needed and help regulate the pressure of the feed material entering feed pump 13.

[0040] Leaching agent inlet 18 is coupled to autoclave vessel 20. The leaching agent inlet 18 is designed to supply the aqueous solution or concentrated acidic solutions, such as sulfuric acid (H2SO4) or hydrochloric acid (HCl), that are commonly used as leaching agents in hydrometallurgical processes to autoclave vessel 20. In some embodiments, the leaching agent received by leaching agent inlet 18 is 95% or greater (e.g., 98%) acid such as, for example, sulfuric acid.

[0041] A seal supply 19 may be coupled to autoclave vessel 20. The seal supply 19 is configured to provide the necessary lubrication cooling, and flushing for seals inside autoclave vessel 20. Seal supply 19 may comprise seal barrier fluids such as water, mineral oil, synthetic oil-based fluids, etc.

[0042] FIG. 1 shows a horizontal Autoclave vessel 20 which serves as the primary reaction vessel of hydrometallurgical system 10. Particularly, autoclave vessel 20 provides the controlled high temperature, high pressure environment used for extracting one or more target metals from a feed material as part of implementing a hydrometallurgical process such as, for example, HPAL processes. Autoclave vessel 20 is coupled between each of the feed inlet 11, the leaching agent inlet 18, and the discharge outlet 30 to define a leaching flow path along which the leaching agent contacts the feed material to form the product discharged from discharge outlet 30. Generally, autoclave vessel 20 comprises a cylindrical body 22 defining an interior, a plurality of product inlets 23 to supply feed material into autoclave vessel 20, a plurality of heating medium inlets 24 to inject heat into autoclave 20, a quench outlet coupled to a quench vessel 16, and a product outlet 26 from which the leached slurry may exit autoclave 20. Autoclave vessel 20 may be made of stainless-steel or specialized alloys designed to withstand the high temperature and pressure environment of system 10. The interior of autoclave vessel 20 is lined with a corrosion resistant material to withstand the highly corrosive acidic environment within autoclave vessel 20. The interior of autoclave vessel 20 is divided into multiple compartments separated2942-06001 by passive agitating elements / baffles 27. Each compartment contains active agitating elements / mechanical agitators 28 (e.g., a mechanical stirrer or impeller) to continuously disperse and mix the acid throughout each compartment. Autoclave vessel 20 also includes a flow path allowing slurry to flow through each compartment.

[0043] A plurality of isolation valves 32 is coupled between feed pumps 13 and autoclave vessel 20 and configured to allow operators control the pressure differential across autoclave 20 ensuring that autoclave 20 operates within its specified pressure range and capacity. The plurality of isolation valves 32 between feed pumps 13 and autoclave vessel 20 may also allow operators adjust the flow rate of the feed material entering autoclave vessel 20.

[0044] In some cases, the leaching process inside autoclave vessel 20 may be exothermic (heat generating). In this instance, steam injection 14 into a steam tank 15 coupled to autoclave vessel 20 is used to maintain the temperature of autoclave vessel 20 at the target or desired temperature and improve overall efficiency of the hydrometallurgy process. In this embodiment, steam is provided through the plurality of heating medium inlets 24 to maintain the temperature inside autoclave vessel 20. For example, steam injection may be used to maintain the temperature inside autoclave vessel 20 at 250oC throughout the leaching process.

[0045] A quench vessel 16 is coupled to autoclave vessel 20 via quench inlet 25. The quench vessel 16 is configured to regulate the temperature inside autoclave vessel 20. For example, when the temperature of the extractive process in autoclave vessel 20 exceeds the normal operating temperature, quench vessel 16 may rapidly cool down the temperature to prevent overheating or thermal runaway, which can result in damage to the equipment.

[0046] A plurality of isolation valves 32, control valve 34, and PRV 36 are coupled between the quench inlet 25 and quench vessel 16. The isolation valves 32 between quench inlet 25 and quench vessel 16 regulate the flow of slurry from autoclave vessel 20 to quench vessel 16, and provide a means to isolate quench vessel 16 in case of an emergency. A control valve 34 is coupled between the plurality of isolation valves 32 and quench vessel 16 to control the temperature, and chemical reaction within autoclave vessel 20. For example, depending on the temperature in the interior of autoclave vessel 20, slurry may flow from autoclave vessel 20 through the plurality of isolation valves 32 and through fluid conduit 38 to PRV 36 which is coupled to quench vessel 16. The PRV 36 is configured to vent excess temperature in the interior of2942-06001 autoclave vessel 20 to prevent overheating and thereby maintain safe operating conditions within autoclave vessel 20. In some embodiments, the slurry in quench vessel 16 may be cooled by dilution with water or addition of coolants.

[0047] Product outlet 26 of autoclave vessel 20 is coupled to flash vessel 17. Flash vessel 17 is configured to depressurize the slurry from autoclave 20 and return the slurry to atmospheric conditions for further processing (e.g., solution concentration and purification, metal recovery, residue processing, etc.). The slurry in autoclave vessel 20 flows over the baffles 27 of each compartment and is eventually discharged to flash vessel 17. Flash vessel 17 may also separate the resulting two-phase mixture (liquid and vapor) and facilitate solids carryover. In this embodiment, flash vessel 17 is coupled to discharge outlet 30 and configured to discharge the slurry containing an extracted target metal that is no longer bound to the original feed material. In some embodiments, flash vessel 17 may comprise multiple stages.

[0048] Referring to FIGS. 2 and 3, an exemplary embodiment of a fluidic device in accordance with principles disclosed herein is shown. Fluidic device 100 and other fluidic devices similar in configuration may be included in hydrometallurgical systems for directing fluid flow therethrough. Particularly, FIG.2 shows a schematic diagram of an exemplary fluidic device 100. The fluidic device 100 includes a generally cylindrical body 102, flange 104 having a plurality of circumferentially disposed holes 105, an interior 106 which extends through the body 102, a valve stem 108 extending from the body 102, a plurality of ports 110 disposed on the body 102, and a plurality of fastener assemblies 112 comprising a plurality of screws, bolts and nuts. The Fluidic device 100 may comprise a single piece or multiple pieces coupled together. The plurality of holes 105 is configured to couple fluidic device 100 to a fluid conduit (e.g., pipe, other fluidic devices, etc.) and provide a seal between fluidic device 100 and the equipment to which it is coupled.

[0049] Referring now to FIG.3, a cross sectional view of fluidic device 100 is shown. In this embodiment, the interior 106 of fluidic device 100 is defined by a contact surface 126 that is lined with a protective coating to resist corrosion in an acidic system (e.g., hydrometallurgical system 10). A valve seat 122 is disposed in interior 106 and comprises a pair of seal rings or seal elements 124 on either side of valve stem 108. The pair of seal elements 124 generally comprises a frustoconical sealing surface and provide metal to metal sealing. The surfaces of the seal elements 124 may also be lined with a corrosion resistant coating. In some embodiments, seal elements 124 is rotatable2942-06001 about a rotation axis 125, which is orthogonal to a central axis 135 of fluidic device 120. The valve stem 108 is coupled to a valve actuator (not shown), which is used to rotate fluidic device 120 about its rotational axis and between its open and closed positions. Actuation of fluidic device 120 may be manual, electric, pneumatic or hydraulic. Fluidic device 120 may also include one or more seal glands 130. Seal glands 130 is used to create a seal around valve stem 108 to prevent fluid leakage.

[0050] Referring now to FIG.4, a cross sectional view of an exemplary flange of the fluidic device of FIG.2 in accordance with principles disclosed herein is shown. Such valves may be included in hydrometallurgical systems for directing fluid flow therethrough. Particularly, flange 150 (similar to flange 104 of FIG.2) may be coupled to a fluid conduit and is configured to provide a secure connection and seal between the fluidic device (e.g., fluidic device 100 of FIG.2) and a fluid conduit. Flange 150 comprises a circular disc 152 having a raised face 154, a plurality of holes 156 (similar to holes 105 of FIG.2) circumferentially disposed around circular disc 152, and a hub 158. The holes 154 allow the flange 150 to couple to a matching flange on another equipment via a gasket and fastener assembly.

[0051] Referring to FIG.5, an image of an exemplary acid injection ball valve 170 with TiO2failure according to some embodiment is shown. Such valves may be included in hydrometallurgical systems for directing fluid flow therethrough. As previously discussed, the biggest challenges to fluidic devices used in hydrometallurgical processes are corrosion and erosion due to the acidic nature, high temperature and high pressure environment. Failure can be seen in acid injection ball valve 170 where the coating 172 and contact surface 174 of the ball valve eroded causing a leak in the hydrometallurgical system.

[0052] Referring now to FIG.6, a schematic diagram illustrating another embodiment of a fluidic device 200 is shown. The fluidic device 200 may be deployed in acidic systems such as in hydrometallurgical systems (e.g., hydrometallurgical system 10) or other acid systems such as, for example, wastewater systems, food processing, oil refining, chemical synthesis, etc. Fluidic device 200 may be in the form of conduits, pipes, tubes, channels and other equipment that may be in contact with a corrosive fluid (e.g., acid). Fluidic device 200 generally includes a body 202 and an interior 204 that extends through the body 202. It should be noted that while fluidic device 200 is shown with a cylindrical body, fluidic device 200 may comprise any shape or size. The fluidic device 200 may include a contact surface (e.g., a central passage) or other parts2942-06001 of fluidic device 200 on which a corrosion resistant coating as further described herein, may be applied. The corrosion resistant coating is applied to prevent corrosion and erosion from fluids that may contact fluidic device 200.

[0053] Referring to FIG. 7, an exemplary coated surface 300 is shown according to some embodiments. In this exemplary embodiment, coated surface 300 includes a base layer or substrate 310, an intermediate layer or bond coat 320, and an outer layer or topcoat 330. In some embodiments, the substrate 310 of coated surface 300 defines a surface 312 and comprises a body of a fluidic device such as a corrosion resistant fluidic device of a hydrometallurgical or other fluidic system and the like. For instance, substrate 310 may comprise a valve, a vessel, a fluid conduit, a pump, and / or any other device that may come into direct contact with a fluid including acidic solutions and the like.

[0054] In this exemplary embodiment, a corrosion resistant coating 301 is defined by the bond coat 320 and the topcoat 330 applied to the surface 312 of substrate 310. The topcoat 320 may comprise a formulation of different materials that may vary (e.g., in kind and / or amount) from a formulation of materials comprising bond coat 320. In some embodiments, the thermal expansion coefficient of bond coat 320 may be similar as the thermal expansion coefficient of topcoat 330 to prevent failure of the corrosion resistant coating 301 in response to heating thereof. In some embodiments, a coefficient of thermal expansion of the bond coat 320 is within 2% to 5% of a thermal coefficient of expansion of the topcoat 330. The bond coat 320 may be adhered between the surface 312 of substrate 310 and the topcoat 320 whereby an exposed surface 332 of the topcoat 330 defines a contact surface of the corrosion resistant coating 301 and may be placed into direct contact with various fluids with corrosion resistant coating 301 serving to protect the substrate 310 covered thereby. The bond coat 320 may augment the adhesion of the topcoat 330 to the surface 312 of substrate 310. In some embodiments, the bond coat 320 may provide the corrosion resistant coating 301 with an adhesion in excess of 10,000 PSI. In certain embodiments, bond coat 320 may provide the corrosion resistant coating 301 with an adhesion in excess of 12,000 PSI.

[0055] In some embodiments, bond coat 320 augments the wear resistance of the corrosion resistant coating 301. For example, bond coat 320 may include wear resistant materials not present (or present in lesser amounts) in the topcoat 330 such as, for instance, tungsten carbide. The wear resistant materials forming the bond coat2942-06001 320 may reduce or minimize erosion of the corrosion resistant coating 301 over the operational life thereof.

[0056] The topcoat 330 of corrosion resistant coating 301 may comprise one or more corrosion resistant materials in various formulations. For example, topcoat 330 may include, among other materials, chromium oxide and barium glass where the content of the chromium oxide may exceed the content of the barium glass. In certain embodiments, the ratio of chromium oxide to barium glass of topcoat 330 ranges from 60:40 to 98:20. In other embodiments, the barium glass is alkali. In some embodiments, the topcoat 330 is between 0.006 inch and 0.011 inch, or less than 0.1 inch. In certain embodiments, the topcoat 330 is configured to resist corrosion in up to 98% acidic solution, at a temperature of 300oC or greater, at a pressure of up to 725 psi or greater, for a period of three years, at least three years, or greater than three years. In other embodiments, a coefficient of thermal expansion of the contact surface is within 2% to 5% of a thermal coefficient of expansion of the corrosion resistant coating.

[0057] In some embodiments, bond coat 320 and / or topcoat 330 may be applied via spray coating. For instance, in an embodiment, at least the bond coat 320 may be applied to the surface 312 of substrate 310 using a high velocity oxygen fuel (HVOF) application process. However, the manner in which bond coat 320 and / or topcoat 330 are applied to the substrate 310 to form corrosion resistant coating 301 may vary in other embodiments.

[0058] Referring to FIG.8, an image of an exemplary coated surface 350 is shown. In this example, coated surface 350 includes a base layer or substrate 360, an intermediate layer or bond coat 370, and an outer layer or topcoat 380. In some embodiments, the substrate 360 of coated surface 350 comprises a body of a fluidic device such as a corrosion resistant fluidic device of a hydrometallurgical or other fluidic system and the like. For instance, substrate 360 may comprise a valve, a vessel, a fluid conduit, a pump, and / or any other device that may come into direct contact with a fluid including acidic solutions and the like. As depicted in FIG. 8, a corrosion resistant coating 351 is defined by the bond coat 370 and the topcoat 380 applied to the substrate 360. The topcoat 380 may comprise a formulation of different materials that may vary (e.g., in kind and / or amount) from a formulation of materials comprising bond coat 370.

[0059] Referring to FIG. 9, an exemplary coating system 400 is shown according to some embodiments. Coating system 400 may apply a corrosion resistant coating 3942942-06001 to a surface 392 of a substrate 390. In some embodiments, the corrosion resistant coating may comprise multiple distinct layers such as the bond coat 320 and topcoat 330 of the corrosion resistant coating 301 shown in FIG. 7. In other embodiments, coating system 400 may apply a single coating consisting of a single layer to the surface 392 of substrate 390.

[0060] In this exemplary embodiment, coating system 400 generally includes an applicator 410, a robotic arm 420, and a computer system 430 for controlling the operation of the applicator 410 and / or robotic arm 420. Applicator 410 of coating system 400 includes a nozzle 412 for projecting a spray 417 of coating material (e.g., a powdered composite material comprising both chromium oxide and barium glass) via a material feeder 415 (e.g., a tubular conduit and the like) against the surface 392 of substrate 390. In some embodiments, spray 417 comprises a plasma spray of a powdered composite material containing chromium oxide and barium glass. In certain embodiments, the content of the chromium oxide is greater than the content of the barium glass in the powdered composite material. In some embodiments, applicator 410 comprises a HVOF applicator including an internal combustion chamber from which the heated coating material is ejected via nozzle 412 at supersonic velocities. In some embodiments, the velocity of the powdered particles contained in spray 417 is approximately up to 2,000 feet per second (ft / s). In certain embodiments, the velocity of the gas contained in spray 417 is approximately up to 10,000 ft / s. In some embodiments, the temperature spray 417 is approximately between 15,000°F and 30,000°F. In certain embodiments, a tip or terminal end of the nozzle 412 of applicator 410 is spaced by a predefined applicator. In certain embodiments, the applicator 410 traverses the surface 392 of substrate 390 at a predefined applicator speed (e.g., indicated by arrow 405 in FIG.11)

[0061] Robotic arm 420 of coating system 400 generally includes one or more links 422 coupled together by one or more corresponding rotary joints 424 with the applicator 410 connected to a terminal end of the robotic arm 420 to define an end effector thereof. In this manner, robotic arm 420 permits applicator 410 to be moved relative to the surface 392 of substrate 390. Particularly, robotic arm 420 may provide applicator 410 with a plurality of degrees of freedom (DoF) relative to a base 425 upon which the robotic arm 420 is mounted. In certain embodiments, the robotic arm 420 provides applicator 410 with five more DoFs although the number of DoFs provided2942-06001 by robotic arm 420 to the applicator 410 may vary depending on the requirements of the given application.

[0062] The computer system 430 of coating system 400 may operate the robotic arm 420 and applicator 410 to form the corrosion resistant coating 394. The computer system 430 may be controlled by a human operator of coating system 400 and / or autonomously in accordance with predefined instructions defining a spray course stored on a memory device of the computer system 430. For example, the computer system 430 may contain instructions plotting a spray course that is based on a geometry of the surface 392 of substrate 390. The instructions may control a velocity of spray 417, the applicator speed 405 relative the surface 392, a temperature of the spray 417, and / or the applicator distance 416 in accordance with one or more predefined coating routines.

[0063] In some embodiments, the surface 392 of substrate 390 is initially prepared prior to applying the corrosion resistant coating 394. For example, the surface 392 of substrate 390 may be initially blasted (e.g., by coating system 400) with silicon carbide powder to provide a thermal barrier along the surface 392. The surface 392 may be subsequently degreased and etched using an acid etching solution. In certain embodiments, the surface 392 is preheated prior to applying the corrosion resistant coating 394.

[0064] Referring now to FIG.10, a flowchart of a method 500 of preparing the corrosion resistant coating material in accordance with principles disclosed herein is shown. Method 500 begins at block 502 with measuring a predefined quantity of a plurality of compounds into a rolling canister. The compounds may be in the form of a powder and includes at least chromium oxide and barium glass, where the chromium oxide content exceeds the barium glass content. The barium glass may be alkali due to the similar thermal expansion coefficients of Alkali Barium Glass and Chromium oxide. In some aspects, other compounds may be included.

[0065] Method 500 continues at block 504 with rolling and / or mixing the plurality of compounds at a predefined speed for a predefined period of time to form a composite or blend and ensure the compounds are completely blended. Mixers, high-speed dispersers etc., may be used to mix the compounds. For example, the plurality of compounds may be mixed at 40 revolutions per minute (RPM), 40-60 RPM, or greater than 60 RPM for 5 minutes, less than 5 minutes or greater than 5 mins. In some instances, mixing the plurality of compounds may be followed by a test spray sample.2942-06001 At block 506, method 500 continues with emptying the resulting composite or blend into a container or canister for storage and / or application to a fluidic device.

[0066] Referring now to FIG.11, a flowchart of a method 600 of applying the corrosion resistant coating material of FIG. 10 to a fluidic device in accordance with principles disclosed herein is shown. Method 600 begins at block 602 with mounting the fluidic device (e.g., fluidic device 100 or 200) onto a fixture and loading an applicator with the corrosion resistant coating material. In some embodiments, block 602 may also include programing a robotic arm for applying the corrosion resistant coating material. Method 600 continues at block 604 with plotting a spray course based on the geometry of the fluidic device and adjusting at least one of the rate, speed or distance of the applicator (e.g., spray gun) to predefined values based on the spray course. At block 606, method 600 continues with loading the corrosion resistant coating material onto a feeder or hopper and setting the control parameters of the applicator based on the desired coating thickness. The parameters may include the alloy material, feed rate, arc temperature etc. Method 600 continues at block 608 with dispensing or spraying the corrosion resistant coating material onto the fluidic device.

[0067] The coatings may be applied (e.g., directly, via plasma arc spray, etc.) to various contact surfaces such as Titanium, Iron, Copper, Nickel, Chromium, Tantalum, Molybdenum, Titanium Alloy, Iron Alloy, Copper Alloy, Nickel Alloy, Chromium Alloy, Tantalum Alloy, Molybdenum Alloy and ceramic materials, etc. The finished coating thickness may be between 0.006 and 0.011 inches or less than 0.1 inches depending on the material of the contact surface. The resulting corrosion resistant coating is a hard coating that prevents adhesive wear, abrasive wear, and chemical corrosion from concentrated acid (e.g., H2SO4). In some embodiments, corrosion resistant coatings described herein provide protection exceeding 36 months when exposed to agitated 99.9% H2SO4 at approximately 300°C. In certain embodiments, corrosion resistant coatings described herein provide protection exceeding seven years when exposed to H2SO4 having a concentration equal to or less than 50%. In some embodiments, corrosion resistant coatings described herein have an adhesion of approximately 12,400 PSI. The corrosion resistant coating also lowers the coefficient of friction between the coated surface and other metallic surfaces which lowers the amount of torque required to operate the fluidic device (e.g., fluidic device 100), and improves the durability, longevity and productivity of valves and associated flow components.2942-06001

[0068] Referring now to FIG.12, a flowchart of another method 650 of applying the corrosion resistant coating material of FIG. 10 to a fluidic device in accordance with principles disclosed herein is shown. Method 650 begins at block 652 with blasting a contact surface of the fluidic device with a silicon carbide (SiC) powder to provide a thermal barrier on the contact surface. At block 654, method 650 continues with degreasing the contact surface. In some embodiments, block 654 comprises immersing the fluidic device in a treatment solution (e.g., BONDERITE CAK LS NP- LT) to clean and prepare the contact surface of the fluidic device for coating. For example, the fluidic device may be immersed in a 60-70oC treatment solution for about 20 mins. At block 656, method 650 continues with etching the contact surface of the fluidic device using an etching solution. For example, a solution which combines a cleaning agent with an acid (e.g., Turco 4104 / HNO3 with a concentration of 1:8 at room temperature for 15 mins). Method 650 continues at block 658 with preheating and thermal spraying the fluidic device. In some embodiments, the time interval between blocks 656 and 658 may not exceed 2-3 hours. In some embodiments, the corrosion resistant material may be applied directly onto the contact surface of the fluidic device.

[0069] Referring to FIGS.13A and 13B, an image illustrating the result of a corrosion test with the corrosion resistant coating deposited on a contact surface using the composition and methods in accordance with principles disclosed herein is shown. Particularly, image 820 of FIG.13A show a 500X (500 times) magnification of a coated contact surface before acid immersion and image 850 of FIG. 13B show the 500X magnification of the same coated contact surface after acid immersion. During repeated corrosion tests, coupons coated with the corrosion resistant coating material disclosed herein (chromium oxide and alkali barium glass coating (Cr2O3-AB)) were immersed in 98% H2SO4 at a constant temperature of 300◦C, for three years. As can be seen in image 820 of FIG.13A and image 850 of FIG.13B, the coupons showed no physical degradation after long-term exposure.

[0070] Referring now to FIGS. 14A and 14B, graphical representations of x-ray diffraction from the repeated corrosion tests illustrated in FIGS. 10a and 10b in accordance with principles disclosed herein is shown. Particularly, FIG.14A shows a graph 920 with intensity of the diffracted ray in arbitrary units (a.u.) plotted on the y- axis against diffraction angle (2θ) on the x-axis pre-acid immersion, and FIG. 14B shows a graph 950 with intensity of the diffracted ray in arbitrary units (a.u.) plotted on2942-06001 the y-axis against diffraction angle (2θ) on the x-axis post-acid immersion. As can be seen, the x-ray diffraction graph 920 of FIG.14A and the x-ray diffraction graph 950 of FIG.14B show no measurable change in the chemical composition of the coated coupons after immersion in the 98% H2SO4 at a constant temperature of 300◦C, for the three years.

[0071] Any of the systems and methods disclosed herein can be carried out (e.g., entirely or partially) on a computer or other device comprising a processor (e.g., a desktop computer, a laptop computer, a tablet, a server, a smartphone, or some combination thereof). Referring now to FIG. 15, a computer system 980 suitable for implementing one or more embodiments disclosed herein is shown. The computer system 980 includes a processor 981 (which may be referred to as a central processor unit or CPU) that is in communication with memory devices including secondary storage 982, read only memory (ROM) 983, random access memory (RAM) 984, input / output (I / O) devices 985, and network connectivity devices 986. The processor 981 may be implemented as one or more CPU chips.

[0072] It is understood that by programming and / or loading executable instructions onto the computer system 980, at least one of the CPUs 981, the RAM 984, and the ROM 983 are changed, transforming the computer system 980 in part into a particular machine or apparatus having the novel functionality taught by the present disclosure. Thus, the RAM 984 and / or the ROM 983 may comprise a non-transitory machine- readable (or computer-readable) medium that may include instructions (which may be referred to herein as machine-readable instructions) that are executable by CPU 981 to provide functionality to computer system 980. Thus, in some embodiments, a machine-readable instructions stored on a memory may be executed on a processor, so as to configured the processor to carry out some or all of the features of the methods described herein.

[0073] It is fundamental to the electrical engineering and software engineering arts that functionality that can be implemented by loading executable software into a computer can be converted to a hardware implementation by well-known design rules. Decisions between implementing a concept in software versus hardware typically hinge on considerations of stability of the design and numbers of units to be produced rather than any issues involved in translating from the software domain to the hardware domain. Generally, a design that is still subject to frequent change may be preferred to be implemented in software, because re-spinning a hardware implementation is2942-06001 more expensive than re-spinning a software design. Generally, a design that is stable that will be produced in large volume may be preferred to be implemented in hardware (for example in an application specific integrated circuit (ASIC),or field-programmable gate arrays (FPGA)) because for large production runs the hardware implementation may be less expensive than the software implementation. Often a design may be developed and tested in a software form and later transformed, by well-known design rules, to an equivalent hardware implementation in an application specific integrated circuit that hardwires the instructions of the software. In the same manner as a machine controlled by a new ASIC is a particular machine or apparatus, likewise a computer that has been programmed and / or loaded with executable instructions may be viewed as a particular machine or apparatus.

[0074] Additionally, after the system 980 is turned on or booted, the CPU 981 may execute a computer program or application. For example, the CPU 981 may execute software or firmware stored in the ROM 983 or stored in the RAM 984. In some cases, on boot and / or when the application is initiated, the CPU 981 may copy the application or portions of the application from the secondary storage 982 to the RAM 984 or to memory space within the CPU 981 itself, and the CPU 981 may then execute instructions of which the application is comprised. In some cases, the CPU 981 may copy the application or portions of the application from memory accessed via the network connectivity devices 986 or via the I / O devices 985 to the RAM 984 or to memory space within the CPU 981, and the CPU 981 may then execute instructions of which the application is comprised. During execution, an application may load instructions into the CPU 981, for example load some of the instructions of the application into a cache of the CPU 981. In some contexts, an application that is executed may be said to configure the CPU 981 to do something, e.g., to configure the CPU 981 to perform the function or functions promoted by the subject application. When the CPU 981 is configured in this way by the application, the CPU 981 becomes a specific purpose computer or a specific purpose machine.

[0075] The secondary storage 982 is typically comprised of one or more disk drives or tape drives and is used for non-volatile storage of data and as an over-flow data storage device if RAM 984 is not large enough to hold all working data. Secondary storage 982 may be used to store programs which are loaded into RAM 984 when such programs are selected for execution. The ROM 983 is used to store instructions and perhaps data which are read during program execution. ROM 983 is a non-volatile2942-06001 memory device which typically has a small memory capacity relative to the larger memory capacity of secondary storage 982. The RAM 984 is used to store volatile data and perhaps to store instructions. Access to both ROM 983 and RAM 984 is typically faster than to secondary storage 982. The secondary storage 982, the RAM 984, and / or the ROM 983 may be referred to in some contexts as computer readable storage media and / or non-transitory computer readable media.

[0076] I / O devices 985 may include printers, video monitors, electronic displays (e.g., liquid crystal displays (LCDs), plasma displays, organic light emitting diode displays (OLED), touch sensitive displays, etc.), keyboards, keypads, switches, dials, mice, track balls, voice recognizers, card readers, paper tape readers, or other well-known input devices.

[0077] The network connectivity devices 986 may take the form of modems, modem banks, Ethernet cards, Omni-Path Architecture (OPA), InfiniBand (IB), universal serial bus (USB) interface cards, serial interfaces, token ring cards, fiber distributed data interface (FDDI) cards, wireless local area network (WLAN) cards, radio transceiver cards that promote radio communications using protocols such as code division multiple access (CDMA), global system for mobile communications (GSM), long-term evolution (LTE), worldwide interoperability for microwave access (WiMAX), near field communications (NFC), radio frequency identity (RFID), and / or other air interface protocol radio transceiver cards, and other well-known network devices. These network connectivity devices 986 may enable the processor 981 to communicate with the Internet or one or more intranets. With such a network connection, it is contemplated that the processor 981 might receive information from the network, or might output information to the network (e.g., to an event database) in the course of performing the methods described herein. Such information, which is often represented as a sequence of instructions to be executed using processor 981, may be received from and outputted to the network, for example, in the form of a computer data signal embodied in a carrier wave.

[0078] Such information, which may include data or instructions to be executed using processor 981 for example, may be received from and outputted to the network, for example, in the form of a computer data baseband signal or signal embodied in a carrier wave. The baseband signal or signal embedded in the carrier wave, or other types of signals currently used or hereafter developed, may be generated according2942-06001 to several known methods. The baseband signal and / or signal embedded in the carrier wave may be referred to in some contexts as a transitory signal.

[0079] The processor 981 executes instructions, codes, computer programs, scripts which it accesses from hard disk, floppy disk, optical disk, solid state drives (SSD) (these various disk-based systems may all be considered secondary storage 982), flash drive, ROM 983, RAM 984, or the network connectivity devices 986. While only one processor 981 is shown, multiple processors may be present. Thus, while instructions may be discussed as executed by a processor, the instructions may be executed simultaneously, serially, or otherwise executed by one or multiple processors. Instructions, codes, computer programs, scripts, and / or data that may be accessed from the secondary storage 982, for example, hard drives, floppy disks, optical disks, and / or other device, the ROM 983, and / or the RAM 984 may be referred to in some contexts as non-transitory instructions and / or non-transitory information.

[0080] In an embodiment, the computer system 980 may comprise two or more computers in communication with each other that collaborate to perform a task. For example, but not by way of limitation, an application may be partitioned in such a way as to permit concurrent and / or parallel processing of the instructions of the application. Alternatively, the data processed by the application may be partitioned in such a way as to permit concurrent and / or parallel processing of different portions of a data set by the two or more computers. In an embodiment, virtualization software may be employed by the computer system 980 to provide the functionality of a number of servers that is not directly bound to the number of computers in the computer system 980. For example, virtualization software may provide twenty virtual servers on four physical computers. In an embodiment, the functionality disclosed above may be provided by executing the application and / or applications in a cloud computing environment. Cloud computing may comprise providing computing services via a network connection using dynamically scalable computing resources. Cloud computing may be supported, at least in part, by virtualization software. A cloud computing environment may be established by an enterprise and / or may be hired on an as-needed basis from a third-party provider. Some cloud computing environments may comprise cloud computing resources owned and operated by the enterprise as well as cloud computing resources hired and / or leased from a third-party provider.

[0081] In an embodiment, some or all of the functionality disclosed above may be provided as a computer program product. The computer program product may2942-06001 comprise one or more computer readable storage medium having computer usable program code embodied therein to implement the functionality disclosed above. The computer program product may comprise data structures, executable instructions, and other computer usable program code. The computer program product may be embodied in removable computer storage media and / or non-removable computer storage media. The removable computer readable storage medium may comprise, without limitation, a paper tape, a magnetic tape, magnetic disk, an optical disk, a solid-state memory chip, for example analog magnetic tape, compact disk read only memory (CD-ROM) disks, floppy disks, jump drives, digital cards, multimedia cards, and others. The computer program product may be suitable for loading, by the computer system 980, at least portions of the contents of the computer program product to the secondary storage 982, to the ROM 983, to the RAM 984, and / or to other non-volatile memory and volatile memory of the computer system 980. The processor 981 may process the executable instructions and / or data structures in part by directly accessing the computer program product, for example by reading from a CD-ROM disk inserted into a disk drive peripheral of the computer system 980. Alternatively, the processor 981 may process the executable instructions and / or data structures by remotely accessing the computer program product, for example by downloading the executable instructions and / or data structures from a remote server through the network connectivity devices 986. The computer program product may comprise instructions that promote the loading and / or copying of data, data structures, files, and / or executable instructions to the secondary storage 982, to the ROM 983, to the RAM 984, and / or to other non-volatile memory and volatile memory of the computer system 980.

[0082] In some contexts, the secondary storage 982, the ROM 983, and the RAM 984 may be referred to as a non-transitory computer readable medium or a computer readable storage media. A dynamic RAM embodiment of the RAM 984, likewise, may be referred to as a non-transitory computer readable medium in that while the dynamic RAM receives electrical power and is operated in accordance with its design, for example during a period of time during which the computer system 980 is turned on and operational, the dynamic RAM stores information that is written to it. Similarly, the processor 981 may comprise an internal RAM, an internal ROM, a cache memory, and / or other internal non-transitory storage blocks, sections, or components that may2942-06001 be referred to in some contexts as non-transitory computer readable media or computer readable storage media.

[0083] In an embodiment, a method of preparing a corrosion resistant coating material comprises measuring a predefined quantity of a plurality of compounds into a rolling canister, wherein the plurality of compounds includes at least a chromium oxide and a barium glass, and wherein a content of the chromium oxide exceeds a content of the barium glass, rolling and / or mixing the plurality of compounds at a predefined speed for a predefined period of time to form a composite or blend, and emptying the composite into a container for storage and / or application to a fluidic device. In some embodiments, a ratio of chromium oxide to barium glass ranges from 60:40 to 98:20.

[0084] A method of applying a corrosion resistant coating to a fluidic device comprises (a) blasting a contact surface of the fluidic device with a silicon carbide (SiC) powder to provide a thermal barrier on the contact surface, (b) degreasing the contact surface, (c) etching the contact surface using an acid etching solution, and (d) preheating and thermal spraying the fluidic device. In some embodiments, the corrosion resistant coating is applied to the fluidic device following (d) with the corrosion resistant coating containing a powdered blend of chromium oxide and barium glass.

[0085] While disclosed embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the systems, apparatus, and processes described herein are possible and are within the scope of the disclosure. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1), (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps.

Claims

AMENDED CLAIMS received by the International Bureau on 18 September 2025 (18.09.2025).1 . A hydrometallurgical system, the system comprising: a feed inlet configured to receive a feed material containing a bound target metal; a leaching agent inlet configured to receive a leaching agent; a product outlet configured to discharge a slurry containing an extracted target metal; and one or more fluidic devices coupled between the feed inlet, the leaching agent inlet, and the product outlet to define a leaching flow path along which the leaching agent contacts the feed material to form a slurry product, wherein a first of the one or more fluidic devices comprises an interior defined by a contact surface, wherein the contact surface comprises a corrosion resistant coating containing chromium oxide and barium glass, and wherein a coefficient of thermal expansion of the contact surface is within 2% to 5% of a thermal coefficient of expansion of the corrosion resistant coating.

2. The system of claim 1 , wherein a content of the chromium oxide exceeds a content of the barium glass.

3. The system of claim 1 , wherein a ratio by weight of chromium oxide to barium glass is equal to or greater than 60:40.

4. The system of claim 1 , wherein a ratio by weight of chromium oxide to barium glass ranges from 60:40 to 98:20.

5. The system of claim 1 , wherein the barium glass comprises alkali.

6. The system of claim 1 , wherein a thickness of the corrosion resistant coating is between 0.006 inches and 0.011 inches, or less than 0.1 inches.

7. (Cancelled)8. The system of claim 1 , wherein the corrosion resistant coating is further configured to prevent adhesive and abrasive wear of the contact surface, and lower a coefficient of friction between the contact surface and other components of the system.

9. An acidic system comprising: one or more process vessels; a feed tank coupled to the one or more process vessels; a scrubber unit coupled to the one or more process vessels; and the system of claim 1 , wherein the acidic system is configured to handle an aqueous solution having a pH value of less than 7.

10. The system of claim 1 , wherein the corrosion resistant coating comprises a bond coat and a separate topcoat that varies in composition from the bond coat.11 . The system of claim 10, wherein the bond coat comprises tungsten carbide.

12. The system of claim 10, wherein a coefficient of thermal expansion of the bond coat is within 2% to 5% of a thermal coefficient of expansion of the topcoat.

13. A method of applying a corrosion resistant coating to a fluidic device, the method comprising:(a) mounting the fluidic device onto a fixture and loading an applicator with a corrosion resistant coating material comprising chromium oxide and barium glass;(b) plotting a spray course based on a geometry of the fluidic device and adjusting a rate, speed and distance of an applicator to predefined values based on the spray course;(c) loading the corrosion resistant coating material onto a feeder and setting control parameters of the applicator based on a desired coating thickness; and(d) dispensing the corrosion resistant coating material onto the fluidic device.

14. The method of claim 13, wherein a content of the chromium oxide exceeds a content of the barium glass.

15. The method of claim 13, wherein a ratio of chromium oxide to barium glass of the corrosion resistant coating material ranges from 60:40 to 98:20.

16. The method of claim 13, wherein the barium glass is alkali.

17. The method of claim 13, wherein the corrosion resistant coating is dispensed as a plasma onto the fluidic device.

18. The method of claim 13, wherein the corrosion resistant coating is configured to resist corrosion in up to 98% acidic solution, at a temperature of 300°C or greater, at a pressure of up to 725 pounds per square inch or greater, for a period of three years, at least three years, or greater than three years.

19. The method of claim 13, wherein a coefficient of thermal expansion of a contact surface of the fluidic device is within 2% and 5% of a thermal coefficient of expansion of the corrosion resistant coating.

20. (Cancelled)

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