Kingston Process Metallurgy Inc. Custom Testing

CUSTOM TESTING

Our experts are capable of providing solutions to challenges related to process design, material of construction, or operational difficulties. KPM specializes in developing an integrated approach in resolving plant and operational issues, using custom test methods and specialized analytical techniques, and coordinating resources in order to rapidly return to the client with an answer on the source of the problem, and a direction to possible solution. When available, standard test methods (ASTM or others) are used. We are experts at handling chemistry related problems, including chemical thermodynamics, but also perform and coordinate physical tests as required. KPM is structured to provide a one-stop laboratory for testing and analysis of operational issues related to material, processes, and chemical interaction.

Click on the testing service for more information on how KPM solves process issues:

CORROSION AND WEAR TESTING

KPM has expertise in solving issues related to corrosion, accretion and wear for materials such as:

  • Steel, stainless, and metallic alloys
  • Refractories and ceramic material
  • Graphite and other specialty materials
Corrosion and wear testing services include:
  • Conventional electrochemical measurements and evaluation
  • Custom testing in specific gas atmosphere or media (aqueous, salts, slag, or others)
  • Custom testing simulating work/plant environment
  • Custom testing under electrolysis condition
  • Other custom testing under strain, temperature, or combination of conditions
Additional tools to characterize the level of corrosion and wear:
  • Surface analysis and non-contact surface profilometry
  • Thermal analysis techniques such as TGA, DTA
  • Microscopy and microanalysis (optical, SEM, microprobe, QEMScan, XRD)
Plus a range of tools for physical testing, physical measurements, and chemical evaluation
MATERIALS COMPATIBILITY

KPM provides comprehensive materials compatibility testing. Materials compatibility is important to consider prior to the design process, but can also be used to diagnose issues with existing operations. Gaining as much information as possible regarding compatibility of the material through the proper testing will enhance process performance and avoid losses from equipment failure and safety hazards. In most cases, a preliminary evaluation through thermochemical calculations and modelling of the system can give clear indication of incompatibilities, and will direct the experimental work.

Similarly to corrosion evaluation, various custom material compatibility tests can be designed and performed, including:
  • Custom testing in specific gas atmosphere or media (aqueous, salts, slag, or others)
  • Custom testing simulating work/plant environment
  • Custom testing under electrolysis condition
  • Other custom testing under strain, temperature, or combination of conditions
If a standard method (ASTM or others) exist, we can apply it or coordinate the work with other certified labs. In some case, KPM may recommend in-plant testing and monitoring; this can be done with the direct involvement of KPM personnel, along with the plant crew.

Various tools can be used for evaluation of the material before and after the material compatibility test, including:
  • Surface analysis and non-contact surface profilometry
  • Thermal analysis techniques such as TGA, DTA
  • Microscopy and microanalysis (optical, SEM, microprobe, QEMScan, XRD)
Plus a range of tools for physical testing, physical measurements, and chemical evaluation
PROCESS INEFFICIENCIES

KPM has expertise in evaluating existing processes and operations to identify process inefficiencies, or to identify opportunities for improvement. The fundamentals of the operation can be reviewed and modeled to determine departure between plant practices and theoretical conditions. Plant sampling campaign can be coordinated to collect samples and data to define heat and mass balance, as required. Experimental work might be recommended. KPM has access to a range of tools and methods to help identify and correct problems related to process inefficiencies.

DATABASE FOR PHYSICAL PROPERTIES

KPM can develop databases of physical and chemical information related to your plant or operations, custom designed to be used by your engineers or operators. The database can be developed into an interactive software. We can use information from the literature, information from our available databases, and plant information provided by the client or collected by our personnel. We can organize plant sampling campaigns to collect samples and data to define heat and mass balance, as required to complete missing data.

SOLUBILITY CURVE DETERMINATION

KPM has performed various projects determining solubility in aqueous systems, molten salts, molten slags, or molten metal systems. This can be done over a range of temperature and pressure, as required. The solubility can be evaluated using a range of chemical analysis methods, including microprobe. The data will be used to generate solubility curves or complete phase diagrams which would not be available in public literature or available database.

DIFFERENTIAL THERMAL ANALYSIS (CUSTOM TDA)

KPM has access to a high precision Netzsch STA 449 F3 Jupiter instrument, combining thermo-gravimetric (TGA) and differential thermal analysis (DTA) capabilities (see website). We however often prefer to use our custom built DTA, which can be used with harsh environment. We have been running DTA under a range of atmosphere, including H2S, H2, CH4, or Cl2. Larger samples can also be used, allowing to test non-homogeneous materials. We can also analyse the off-gas from the custom DTA using gas analyzers (SO2/O2, CO/CO2) or using our residual gas analyzer (RGA - a quadrupole 300 amu mass spectrometer - MKS Cirrus 2: website ).

THERMO-GRAVIMETRIC ANALYSIS (CUSTOM TGA)

KPM has access to a high precision Netzsch STA 449 F3 Jupiter instrument, combining thermo-gravimetric (TGA) and differential thermal analysis (DTA) capabilities (see website). We however often prefer to use our custom built TGA, which can be used with harsh environment. We have been running TGA under a range of atmosphere, including H2S, H2, CH4, or Cl2. Larger samples can also be used, allowing to test non-homogeneous materials. We can also analyse the off-gas from the custom DTA using gas analyzers (SO2/O2, CO/CO2) or using our residual gas analyzer (RGA - a quadrupole 300 amu mass spectrometer - MKS Cirrus 2: website ).

PROBE DEVELOPMENT (LEVEL, OXIDE, ETC.)

KPM has developed probes for specific application, such as level measurement in harsh environment, measurement of liquid interface (e.g. metal/salt interface), or oxide level in molten salt. Various chemico-physical properties can be used to develop a new concept, or adapt an existing probe design to a specific environment application.

EVALUATION OF GAS SCRUBBING AGENT

KPM developed specific protocol to test and compare various gas scrubbing agent. Methods can be adapted to the specific process. We have been testing liquid and solid (powder injection) gas scrubbing media.

BURNER/AIR EMISSIONS

KPM can design and set-up specific test methods to evaluate and compare burner performance. We also have partnership with experts in air emission sampling who can collaborate for sampling off-gas from our test rigs or from plant stacks. We would then integrate and interpret the results.

CUSTOM IN-LINE GAS ANALYSIS

KPM has expertise in planning and performing plant sampling campaigns, including in-line gas sampling and in-line gas analysis.

Please contact us for information on any of the custom testing services listed above.