Uranium, a heavy metal essential for global nuclear energy production, is extracted from ore using leaching tanks that separate the element and bring it to the surface. Two of the world's longest-operating uranium processing sites, Ranger in Northern Australia and Rossing in Namibia, have been in operation for many years. However, recent incidents involving leaks caused by faulty tank linings and corrosion have raised serious concerns about safety and infrastructure integrity.
In December, the Ranger plant in Australia faced a major environmental incident when over 1 million liters of liquid uranium leaked from a three-story steel leaching tank. The leak was traced back to a damaged lining, which led to severe internal corrosion. This event followed a similar spill just days earlier at Rio Tinto’s Rossing mine in Namibia, highlighting a growing pattern of equipment failure.
The collapsed tank at Ranger, which held 1,450 cubic meters of material, developed a hole that caused extensive wall corrosion. Eventually, the tank split and fell, damaging nearby equipment such as a crane. Inspections later revealed that one of the six tanks showed similar signs of corrosion. Experts believe the issue stems from both aging infrastructure and poor maintenance practices. With all the mine’s pipes, pumps, and tanks having exceeded their 30-year design life, the risk of further failures is increasing.
Corrosion is a widespread problem affecting steel structures globally. It's not a matter of "if" but "when" it will occur. Fortunately, solutions like HJ3’s CarbonSeal carbon fiber system can prevent such issues. Recently, a geothermal power plant with severe corrosion on its primary clarifier and demister tanks turned to HJ3 for restoration. The clarifier, standing 43 feet tall with a 125-foot diameter, had significant structural damage due to corrosion, compromising its integrity.
Four key areas were repaired: a wall patch, the connection between the tank wall and dome roof, the dome itself, and a 36-inch overflow pipe. The steel surfaces were prepared through abrasive blasting and priming. A high-modulus paste was applied, followed by the installation of CarbonSeal carbon fiber. A chemical-resistant topcoat was added for long-term protection. The repair provided the necessary 20-psi hoop strength to the vessel, ensuring structural stability.
To date, HJ3 has successfully reinforced four clarifiers, two demisters, and one rock muffler for this client, saving them 80% in replacement costs. Additionally, the project resulted in environmental benefits, preventing 602 tons of steel from being discarded and avoiding 1,183 tons of CO2 emissions and 36 million gallons of water usage—by eliminating the need for new steel tanks.
If you’re facing corrosion or structural issues with your steel tanks and are looking for an effective, sustainable solution, consider HJ3’s CarbonSeal system. Contact HJ3 today to learn more about how we can help protect your infrastructure.
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