Coral Valves
Case Study: SlurryFlo Control Valves Transform Mining Operations
Client’s Challenge:
A Mining company near South Africa faced a significant issue – their 20-inch Titanium Butterfly valves repeatedly failed after just one month of use. The company turned to SlurryFlo to solve this costly problem. SlurryFlo’s mission was clear: design a solution that would eliminate the frequent replacements of their high-performance control Butterfly valves. The application involved venting steam vapor from flash vessels, which contained corrosive acids and fine particles. The frequent failure of Titanium Butterfly valves led to regular downtime, repair costs, and production losses. (Fig.1)
Additionally, the design of the Titanium Butterfly valves, with an in-line butterfly disc, accelerated abrasive fluids toward the downstream pipe walls, causing premature damage to expensive titanium pipe sections (Fig. 2).
SlurryFlo’s Solution:
SlurryFlo’s engineering team, after analysing process conditions and modulating data, introduced a ‘dual purpose’ trim design (Fig. 3). When the gate opens, it reveals two small ceramic orifices for steam venting (Fig. 4). After venting the flash vessel, the gate can be further retracted for increased flow, all while maintaining centred flow within the pipe (Fig. 5).
By replacing their Titanium butterfly valves with SlurryFlo control valves, the client quickly realized a remarkable return on investment. In the first inspection (one month after installation), the maintenance team noted minimal erosion on wear components. Given the excellent condition of downstream piping, the valves were operated for several months between inspections. After a continuous 12 months of service, only the valve trims needed replacement before reinstalling them.
Financial Benefits:
A comprehensive financial analysis over a five-year period compared the newly engineered SlurryFlo Control valves with the previously used Titanium Butterfly valves that failed prematurely under severe conditions. Factoring in valve refurbishment and replacement costs based on the plant’s history, the results were astounding. Continuing with the existing Butterfly Valves would have cost the client a staggering $66 million. In contrast, the SlurryFlo Titanium Control valves, including initial purchase and ongoing trim replacements every 12 months, cost the client $2.1 million, resulting in an incredible total savings of $63.9 million over five years (based on six valves).
SlurryFlo’s Innovation in Slurry Control Valves:
SlurryFlo’s patented design centres flow uniquely, diverting abrasive particles away from pipe walls and directing flow through the valve’s centre. This design not only protects the valve’s body and downstream pipe but also extends service life significantly. Their variable orifice technology outperforms all control valves in severe slurry service, offering service life 3-10 times longer than other “Severe Service” control valves. After a long service life, a straightforward trim replacement resets the clock.
Coral Valves are the Proud Exclusive Southern African Agents for SlurryFlo Valves. Contact us for all your severe slurry valve needs, including Knife gate valves, SLURAX abrasive slurry butterfly valves, and more options for demanding mining applications.
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