Secure Smelter Solutions: Heavy-Duty HDPE Geomembranes for Corrosion-Resistant Leachate & Process Water Containment

The Critical Challenge: Containing Aggressive Smelter Byproducts
Mining and smelting operations generate highly corrosive effluent streams laden with sulfuric acid, heavy metals (Cu, Zn, Ni, Pb), dissolved salts, and elevated temperatures. Traditional containment materials degrade rapidly, risking:

• Groundwater Contamination from arsenic/cyanide leaks

• Regulatory Non-Compliance with EPA RCRA/ CERCLA standards

• Infrastructure Corrosion costing millions in unplanned repairs

• Production Shutdowns due to environmental incidents

Our Solution: Metallurgical-Grade HDPE Geomembranes
Engineered for extreme smelter environments, our high-density polyethylene liners deliver unmatched chemical resistance and structural integrity for:

• Acid Leachate Ponds

• Process Water Balancing Tanks

• Spent Electrolyte Containment

• Slag Slurry Impoundments

• Emergency Overflow Basins

5 Core Advantages for Smelter Applications

1. Unrivaled Chemical Resistance

• Withstands pH 1-14 extremes – stable in concentrated H₂SO₄, HCl, NaOH solutions

• Immune to heavy metal ion degradation (Cu²⁺, Zn²⁺, Ni²⁺ permeation <0.001 g/m²/day)

• Resists oxidizers like hydrogen peroxide and chlorine bleaches

2. Thermal Stability Under Process Conditions

• Operational range: -60°C to +80°C

• Maintains flexibility during steam surges and freezing slag discharges

• Low thermal expansion coefficient prevents stress cracking

3. Engineered Mechanical Robustness

4. Seam Integrity Assurance

• Double-Track Fusion Welding with 100% spark testing

• Seam strength ≥90% parent material

• Robotic welding available for zero-defect critical zones

5. Cost-Effective Lifecycle Protection

• 50+ year service life reduces replacement frequency

• Prevents $250k+/acre remediation costs from containment failures

• Allows thinner concrete sub-layers (saves 30% on civil works)

Installation & Protection Protocol

Defense-in-Depth System Design:

1. Geotextile Cushion (400g/m²) – Prevents puncture from slag debris

2. HDPE Primary Liner (2.5mm) – Chemical barrier

3. Leak Detection Grid – 30m spacing sensors

4. Secondary HDPE Liner (1.5mm) – EPA-mandated redundancy

Smelter-Specific QA/QC:

• Bath Testing for seam integrity using 5% HCl solution

• Spark Testing at 15kV for micro-pinhole detection

• Differential Scanning Calorimetry validates resin formulation

Regulatory Compliance Enabled

• Meets EPA 40 CFR 264.221 for surface impoundments

• Certified to EN 15382 for hazardous liquid containment

• NSF/ANSI 61 for potable water contact (dual-use ponds)

Proven in Extreme Environments:

“After 12 years containing pH 0.8 sulfuric acid effluent at 65°C, our 2.5mm HDPE liner shows <0.1% elongation loss and zero seam failures.”
– Site Engineer, Copper Smelter, Arizona