Consulting Services

Industry Leading Expertise in Autoclave Design and Operation

Design Review

The earlier in the design process that we can give input, the better — as early as pre-feasibility.

NOVA Hydromet’s team can help prevent problems at your site before they occur. Our design review service will have our controls, process, and product experts reviewing your plans for new plant design, plant expansion, or process changes.

NOVA Hydromet can also assist with proper valve and line sizing using mathematical modeling of flashing, multiphase flow. Our analysis gives insight into optimal system control philosophy to maximize throughput, reduce downtime, and extend equipment life.

We offer expertise in consulting, autoclave circuit modelling, manufacturing and diagnostics, along with equipment sales, service, and repair.

Letdown System Sizing

Incorrectly sized letdown components can cause throughput limitations which take months to detect, control valve trim crushing issues, and persistent line erosion. Whether your system uses an autoclave, flash vessel, or another setup, NOVA can assist with the proper sizing of inlet lines, outlet lines, sparge tubes, flash vessel height and diameter, control valves trim, flow chokes, and blast tubes, all based on achieving optimal flow and velocity.

Letdown Flow Modelling

Modelling flow velocity, pressure, and kinetic energy over the full range of possible flows is essential to achieving an accurate idea of the erosive potential of potential operating conditions. Using mathematical models based in fluid flow theory, NOVA will map flow characteristics for the entire range of possible flows to determine the correct seat size for each angle control valve.

Control Philosophy

Control philosophy for letdown systems should consider the counterintuitive flow characteristics of multiphase flashing flow. Certain operating regimes can be particularly damaging, even at low flows. NOVA can help extend equipment life and prevent unscheduled downtime by recommending a bespoke control philosophy for each letdown system, based on quantitative mathematical modeling results.

Process Analysis

NOVA performs classical process analysis to balance and optimize autoclave reaction performance. Mass and Energy Balancing allows simulation of startup and shutdown procedures and forecasts autoclave temperature. Reaction Kinetics modeling helps optimize reactant inputs and overpressure to get the highest ore yield.

Root Cause Analysis

Failures and broken valve trim are often the result of a series of events rather than just one.

We have found that when autoclave components fail, it is best to take a disciplined scientific approach to finding the root cause of the failure so that it can be resolved, rather than trying to use intuition or ‘gut feel’.

Our subject matter experts have experience triaging hundreds of broken components using a multi-disciplinary approach, including fracture mechanics, multiphase flow theory, operating data analytics, and physical inspections.

In addition to root cause analysis for discrete failures, we can help your site track the lifecycle of problem components to help quantify component life trends and improvements.

System Modelling

A disciplined scientific approach to resolving systemic throughput issues.

Systemic issues in autoclave operation, such as restricted throughput or consistent poor equipment life, will benefit from physics-based modelling.

NOVA's physics-based models take the guesswork out of predicting how your autoclave systems will function under a given set of parameters. Our team can assist by creating models that mirror the specific setup and physics of your autoclave systems.

The models act as digital twins which can then be used to train personnel on how your process functions, run what-if scenarios for predicting autoclave behavior, and troubleshoot control issues. All with the goal of optimizing production.