What are the monitoring methods for mining mixing tank corrosion during long-term operation

Mining mixing tanks are core equipment for slurry processing and chemical mixing. Over long-term operation, they are susceptible to varying degrees of corrosion due to slurry corrosion, wear, and chemical reactions. Corrosion not only shortens equipment lifespan but also leads to production interruptions and increased maintenance costs. Scientific and systematic corrosion monitoring is crucial for ensuring safe operation and improving production efficiency.

1. Visual Inspection

Visual inspection is the most intuitive corrosion monitoring method. Regular inspections of the tank's inner walls, agitator shafts, impellers, and inlet and outlet areas can reveal localized corrosion, rust, flaking, or holes. Visual inspection is suitable for early corrosion detection and can also help assess the combined effects of mechanical wear and chemical corrosion. Combined with high-intensity lighting or an endoscope, visual inspections can penetrate blind spots and promptly identify potential corrosion risks.

2. Thickness Measurement

Measuring tank metal thickness is an important method for quantitatively assessing corrosion. Ultrasonic thickness gauges can measure different locations on the tank, both during operation and during shutdown, to record thickness trends. Regular measurements can determine corrosion rates and identify high-risk areas. Thickness measurement is easy to operate and provides intuitive data, making it suitable for frequent monitoring and long-term tracking, providing a basis for corrosion protection design and maintenance.

3. Electrochemical Monitoring Method

Electrochemical monitoring uses corrosion current, potential, or polarization curves to assess tank metal corrosion. Common methods include electrochemical impedance spectroscopy (EIS), polarization curve analysis, and linear polarization. By installing electrodes at key locations on the tank, changes in corrosion current are monitored in real time, accurately reflecting the corrosion rate of the metal surface. This method is highly sensitive and can be used for online monitoring, making it suitable for highly corrosive slurries and continuously operating mixing tanks.

4. Coating and Corrosion Indicator Monitoring Method

Coating monitoring and corrosion indicator methods use visual or chemical reactions to determine the corrosion status. Delamination, blistering, or discoloration of the anti-corrosion coating surface indicates possible corrosion of the substrate. Corrosion indicators can indicate changes in the acid-base environment or localized corrosion through color changes. This method is easy to operate and suitable for quickly assessing the extent of tank corrosion, especially under chemical treatment and high-temperature slurry conditions.

5. Online Sensor Monitoring Method

Modern mining companies are increasingly adopting online sensor technology to monitor mixing tank corrosion. Sensors can measure liquid pH, conductivity, temperature, flow rate, and corrosion rate, enabling continuous, automated monitoring. Online data can be analyzed in real time by the control system, providing early warning of potential corrosion risks. Sensor monitoring reduces the frequency of manual inspections, improves safety, and provides data support for intelligent slurry processing.

6. Vibration and Acoustic Monitoring

Vibration and acoustic monitoring are primarily used to detect structural weakening or crack propagation caused by corrosion. When the tank is subjected to slurry erosion and mechanical agitation, corroded areas may generate abnormal vibration or acoustic signals. By installing accelerometers or acoustic sensors and analyzing changes in vibration patterns, localized corrosion and structural defects can be identified. This method is suitable for large mixing tanks and continuously operating environments, complementing traditional corrosion detection methods.

7. Regular Sampling and Chemical Analysis

Taking slurry and water samples from the tank and analyzing dissolved metal ion concentration, pH, and redox potential can indirectly assess the corrosion status of the tank. Elevated metal ion concentrations often indicate active corrosion of the tank material. Regular chemical analysis, combined with thickness measurement and visual inspection, can comprehensively assess corrosion trends and provide a scientific basis for preventative measures.