FOUNDRY VALVES FOR MINING'S TOUGHEST DUTIES

EXTENDING LIFESPAN 8X: A Slurry Valve Case Study in Copper Mining

In the high-stakes world of mineral processing, equipment failure directly translates to lost revenue. This case study outlines how a major Chilean copper mine solved a chronic and costly problem of premature valve failure in their most abrasive process line by implementing a purpose-built, engineered slurry valve solution.

The Challenge: Catastrophic Failure in a High-Wear Environment

The mine's primary tailings line was a major operational bottleneck. The combination of high-velocity flow and a high concentration of sharp, abrasive silicate particles was destroying the incumbent resilient seated butterfly valves. The standard EPDM liners were being torn and eroded within 3-4 months, leading to catastrophic leaks, environmental risks, and costly, frequent shutdowns for valve replacement. The maintenance team needed a valve that could survive, not just temporarily exist, in this environment.

The Solution: The Engineered Slurry-Service Butterfly Valve

• Liner Material Science: The core of the solution was a liner made from a proprietary, high-rebound natural rubber compound. Unlike standard elastomers that tear, this material is designed to deform upon impact with abrasive particles and immediately return to its original shape, drastically reducing material loss from erosion.
• Liner & Body Design: The liner was designed to be extra-thick, providing a substantial wear allowance. Crucially, it was also field-replaceable, allowing the mine to simply swap the liner instead of the entire valve, significantly reducing long-term costs. The valve body was a heavy-duty Lug style, allowing for easy installation and removal.
• Disc Protection: The standard stainless steel disc was replaced with one made from Duplex stainless steel and coated with an additional layer of hard-wearing tungsten carbide, protecting it from the abrasive flow when the valve was in a throttling position.

The Result: A New Benchmark for Reliability

The implementation of the JRVAL slurry-service valve fundamentally changed the plant's maintenance strategy. The first valve installed is still in operation after 26 months, representing an 800% increase in service life. The success led the client to specify JRVAL valves as the standard for all abrasive slurry and tailings applications across the site, resulting in a dramatic increase in plant availability and a significant reduction in overall maintenance expenditure.