Challenge:

Mining Client at their mineral processing plant had a significant challenge with valves, plug, retainer and lugs. Component failures were imminent due to extreme temperature of around 275° C and bombardment of the plug and inserts by mineral particles at high velocity. Typically, the plug needs replacing at 8 to 10-week interval contributing to unplanned maintenance, poor asset performance, utilization and significant cost.

Approach:

Our Team @ TRICON worked with the client and integrator to understand the root cause. We undertook rigorous auditing of the valve assembly, performance, severity of damages and an extensive analysis of the material, composition and operational statistics.

Solution:

With a complete understanding of the challenge, root cause and material composition we engaged our global specialist. Our engineers in conjunction with our business partners identified the root cause. We collaborated with engineers with extensive background in mineral processing, material science, valve technology and manufacturing to re-design the plug head and plug with exotic material specification to enhance asset life.

Outcome:

Prototype of the plug and accessories were manufactured at a facility in collaboration with our experts. The plug and components were re-engineered with reliable wear resistant surface engineering solution to enhance asset life. Now the asset enduranceexceeds50 to 60 weeks; delivering over 800% Return on Investment. The proprietary design – manufacture was completed and TRICON holds this specially designed stock exclusively for our client.

• Lead-time:Fast turnaround; 6 – 8 Weeks
• Stock: Spares held at site and TRICON Perth & Kalgoorlie
• Benefit:Asset utilization | Productivity | Planned maintenance

Segment	Mineral & Chemical
Product Type	80mm AA Valve Stem & Gland
Temperature	>270 ° C
Velocity	> 30 – 40 m/s
Pressure	Not Critical
Lead-Time	10 – 12 Weeks(initially)
ROI	600%