Hydrotransportation

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Industrial Rubber Products Irathane
SystemsIracore International
Hydrotransportation Tailings Piping System
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Irathane / Iracore Pipe LiningContents

• History Background
• Advantages Solutions
• Value
• Irathane Polyurethane
• Iracoupling
• Design Accomplishments
• Fittings End Configurations
• Cold Bending
• Quality Assurance

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Polyurethane in Slurry Pipelines

• Spun cast polyurethane lining has emerged as a
  technologically superior material for abrasion
  control in slurry pipelines. Polyurethane lining
  has both chemical and mechanical advantages over
  alternative materials, such as rubber lining,
  high density polyethylene, and hardened steel.
  Some of the benefits of this type of lining
  include extremely long life (projected to be up
  to 20 years or more), lower maintenance costs,
  and the ability to ensure an environmentally
  sound system. Many key mining companies around
  the world have selected polyurethane as the only
  material suitable for critical duty applications
  and are enjoying very successful operation.
• The most effective method of controlling
  excessive abrasion in slurry pipelines is to
  provide a highly abrasive resistant, low
  coefficient of friction material to line the
  pipe. Further, the internal bore of the pipe
  joints should line up to minimize turbulence at
  the joints in order to maximize wear life.
• The performance of any particular lining system
  is directly related to the conditions encountered
  during the operational life of the pipeline.
  These conditions typically include pressure,
  velocity, temperature, chemical makeup, percent
  solids, and particle size distribution of the
  slurry. Therefore, before any lining selection
  is initiated, the environmental and operational
  conditions of the pipeline must be well
  understood. The characteristics of polyurethane
  lined pipe have been shown to effectively meet
  the requirements of a broad range of projects.

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Major Pipe Projects

• Over 625,000 linear meters around the world!

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Irathane Systems Inc. Long Life Pipe Experience

• Our long run of successful pipe lining projects
  with our first generation pipe lining urethane,
  Irathane 2855, includes over 625,000 linear
  meters of lined pipe with some projects which
  were installed years ago and are still in service
  today.
• Asarco/Troy Montana, USA In service since 1981
• Kennecott Copper/Chino New Mexico, USA In
  service since 1981
• New Zealand Steel New Zealand In service since
  1984
• Codelco Chile In service since 1984
• Samarco Brazil In service since 1992
• Pinto Valley Arizona, USA In service since 1994
• Kennecott Utah, USA In service since 1995
• LaCandelaria Chile In service since 1994/1997

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Product Lines and Compounds
Pipe Lining Systems
IRACORE
Rubber
IRATHANE
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Partial Listing of Irathane / Iracore Lined
Piping Projects
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Polyurethane Casting Machine

• Presently operating the largest polyurethane
  machines in the world
• Urethane casting at 3 locations with multiple
  machines

30 kg/minute 140 kg/minute 275
kg/minute
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Proprietary Product Solutions
Products are designed to address the challenges
presented by demanding industrial applications

• Abrasive particles of varying sizes
• Corrosive materials with varying chemical
  properties
• Extreme temperature differences (interior vs.
  exterior)
• Wear performance in light of high velocity
  transportation
• Risk of work injury from equipment installation
  and maintenance
• Maximizing the speed/effectiveness of all mining,
  transporting and processing functions
• Impact and wear/tear from harsh external
  environments
• Minimizing equipment replacement and maintenance
• Minimizing the use of costly and hard-to-find
  skilled labor

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Relative Life Expectancy General Tailings
Hydrotransportation Service

• Worst Wood
• Concrete
• Special Steels
• High-Density Polyethylene
• Polybutylene
• Natural Rubber-Lined Pipe
• Best Polyurethane-Lined Pipe
• Best Ever Irathane/Iracore Polyurethane Linings

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H-18 Taber Abrasion IndexPolyurethane vs. Other
Materials

• Product Weight loss in mg/100 cycles
• Polyurethane (MDI-PTMG) 25.0
• Natural Rubber 430.0
• AR Steel Plate 487.0
• UHMW Polyethylene 83.0
• Linear Polyethylene 184.0

Based on the Taber Abrasion Test as described in
ASTM D1242, ASTM D1044, and ASTM C501
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IRACORECourse Phosphate Pipe Performance and
Value

• Material coarse phosphate
• -15mm particle size
• 60 solids
• 3.05 meters/second

• Hydrotransportation Tailings Pipe Line System

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Information based off of data from actual
phosphate producer.
Projected Life 20 Years
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IRACOREOil Sands Performance and Value

• Material - oil sands
• -125mm particle size
• 46 solids
• 4.70 meters/second

• Hydrotransportation Tailings Pipe Line System

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Irathane Pipe Offers Superior Value
Pipe Product Comparison-Oil Sands
Hydrotransportation
Pipe System Value Comparison

• _______________________________
• Unprotected Steel A-139, 30 diameter, .75
  wall, ERW Pipe
• Irathane and Iracore Coated Steel A-139, 30
  diameter, .375 wall, Spiral Weld Pipe

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Iracore / Irathane PipeOffers Superior Value
IRACORE Pipe System Performance
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Iracore / Irathane Pipe
Technology-Leading Hydrotransportation and
Tailings Pipe System
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Irathanes / IracoresPolyurethane
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Irathanes Polyurethane Advantages

• Basic in prepolymer formulation production
• Manufacture our own compounds, developed for
  specific applications
• Considered premier urethane compound
• Highest quality polyurethanes in the industry
• Longest lasting polyurethane

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Key Factors for Selecting the Proper Urethane
Elastomer

• Hydrolytic Stability
• Durometer Hardness
• Tensile Strength
• Elongation
• Tear Strength
• Resilience
• Abrasion Resistance
• Compression Set
• Chemical Resistance
• Temperature Range

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Why Consider Irathane / Iracore Lined Pipe

• Improved wear life over steel pipe and other
  linings such as stainless, chromium carbide
  overlay, hardened steels and other elastomers
• Eliminates misalignment of pipe ends that causes
  turbulence and premature wear/erosion
• Welded ends (Iracoupling) Replaces costly flanges
  utilized in other elastomer lined pipe systems
  and allows rotation of long lengths of pipe. The
  Iracoupling can be profiled to have a Finite
  Element Analysis up to 200 bar.
• Continuous Monitoring System (CMS) for
  continuous, wireless monitoring of lining
  wear/erosion
• The lining is permanently attached with
  Irathanes proprietary adhesive system (not lose
  fitting i.e. HDPE)
• Projected 20 year life wear service in most
  applications

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IRACOUPLING

• Hydrotransportation Tailings Pipe Line System

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IRACOUPLING
This coupling permits lined pipelines to be
welded where otherwise heavy expensive bolted or
mechanical would have been required.
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IRACOUPLING
The coupling halves are shop welded to pipe prior
to lining with urethane and a specially machined
end profile is formed on the urethane lining to
enable the end faces of the lining at the joint
to be under compression, thereby forming a
positive seal and providing a smooth transition
across the joint, thus eliminating turbulent
slurry flow.

• Welded end flange system allows field welding and
  installation
• Improved rotation of long lengths of pipe up to
  300 meters
• The positive seal provides a smooth transition
  cross the joint
• Bore-to-bore match eliminates unnecessary flow
  turbulence
• Mitigates against environmental events with the
  four seal system
• The urethane face is designed with a double seal
  system
• The Iracoupling is welded
• The cooling annulus is filled with a urethane
  epoxy

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Bore to Bore Match Seal
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Iracore lined pipe with Iracouplings installation
above ground
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Iracore lined pipe with Iracouplings installation
below ground
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IRACOREDesign Accomplishments

• Hydrotransportation Tailings Pipe Line System

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IRACORE? Design Accomplishments

• Developed a lining material that withstands the
  harsh environments and also outperforms other
  wear/erosion materials.
• Developed a lining system with perfect bore to
  bore match to eliminate turbulence
• Designed a welded end system for elastomer lined
  pipe that ensures proper pipe joint alignment
  with multiple level sealing arrangement (leak
  proof).
• Developed an elastomer which allows the use of
  alternative types of steel pipe (such as thin
  wall spiral weld pipe) which provides significant
  cost savings.
• Provides considerable cost savings due to
• Longer life or sustainability
• Less maintenance
• Fewer rotations
• Reduced inspection times
• Reduced manpower requirements
• Lower friction factor
• Lower pumping costs
• Better thermal insulation

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Bore-to-Bore Matching
Alignment Ring for end alignment
Irathane/Iracore LiningLongest proven service
life
Bore-to-Bore Matching
Field welded joint for elastomer lined pipe
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Iracore Lining - Friction

• Temperature Range -10º C to 95º C
• Friction Factor C Factor 157
• Hazen Williams Friction Loss Equation
• Assumption 4.7 meters/second flow rate
• Diameter 30 diameter
• Pipe Length 3,400 meters

Example of comparison friction loss calculations
of various pipe materials using the above
assumptions.
Significant reduction in pumping costs.
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IRACOREEnd Configurations Fittings

• Hydrotransportation Tailings Pipe Line System

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Pipe Coupling ConfigurationsAll With Integral
Gaskets
Victaulic Abrasion Corrosion
Flanged Flat Face Raised Face Ring Groove
Welded Iracoupling
Plain End Square Wrap Around
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Pipe Fittings Capabilities

• Elbows
• Slow Radius Bends
• Tees
• Branched Runs
• Wyes
• Thread-o-let
• Expansion Barrels
• Reducers
• Reducing Tees
• Flex Hose

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Irathane LinedDead Cast Elbow
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IRACORECold Pipe Bending

• Hydrotransportation Tailings Pipe Line System

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Quality Assurance

• Total Quality Management

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Quality Assurance
Quality, Safety and Training
Total Quality Program

• Comprehensive quality and operating manuals
  detail and define all functions and processes
• Traveler system provides traceability of all
  material and finished goods throughout all phases
  of manufacturing
• Several inspection points are located throughout
  all the critical process steps
• All employees receive training on an annual basis