Mitigation of concrete corrosion in potash mine and milling operations

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The natural resource sector is an important part of Canada's economy. Of the many natural resources that are mined in Canada, potash mining is centred in Saskatchewan. Potash mining has created a significant number of jobs in Canada, and, in 2013, potash production was valued at $5.6 billion with $16.4 billion worth of investment by potash producers expected in the province over the next 20 years. Corrosion, particularly concrete corrosion, represents a significant safety and environmental issue for potash mine and mill operations. Concrete corrosion is accelerated in a potash mill environment because of the high chloride content in potash production. The corrosion of reinforcing bar (rebar) in concrete leads to the cracking and spalling of concrete. The objective of this research program, to be performed in collaboration with Mosaic, Agrium, Potash Corporation of Saskatchewan, and BHP Billiton through the International Mineral Innovation Institute (IMII), is to test the effectiveness of polystyrene sulfonate coated rebar on restricting chloride ingress to the rebar surface so as to restrict the corrosion of rebar. The effect of concrete composition on the degree of corrosion that occurs will also be investigated. The comprehensive study of concrete corrosion will involve electrochemical experiments and synchrotron radiation studies using multiple beamlines at the Canadian Light Source (CLS). This research program will provide considerable information on the effect of coated rebar and concrete composition on mitigating concrete corrosion. This research program is part of a broader Saskatchewan based initiative to understand the effect of various forms of corrosion on potash mine and mill operations so to develop corrosion mitigation strategies. Expanding the potash industry will require a reduction in environmental impact and increase in safety to ensure sustainability, which this program seeks to address.