Mining operation extends valve maintenance interval from 6,000 to 28,000 operating cycles

Advanced flow control technologies can solve a common issue in filter press processes involving abrasive materials: the accelerated wear of conventional valves, leading to unplanned downtime.

This was the challenge faced by a Chilean mining company, where valve replacement was required every 6,000 operating cycles due to extreme operating conditions. A recurring problem was the frequent need to replace valves or spare parts. From a material standpoint, traditional valves were not suitable for operating under conditions of high pressure, high abrasion, and extreme temperatures.

Frequent valve replacements and equipment wear impacted process efficiency

In addition to frequent valve replacements, inefficiencies in flow control and equipment wear were generating high maintenance costs and unplanned shutdowns, reducing overall process efficiency.

There were also operational limitations and risks of system blockage at low flow rates, creating additional challenges for reliable operation.

Ceramic valve solution improves durability in severe service

Solid ceramic components and a full bore design help the Neles™ E-series valve reduce maintenance costs and improve uptime in abrasive slurry applications.

To address these challenges, Valmet recommended replacing traditional valves with ceramic ball valves combined with automated and intelligent flow control.

One of the key differentiators of the Neles™ E-series ball valves is the use of advanced non-metallic materials. These materials were strategically incorporated into the valve design to withstand the extreme conditions and high levels of abrasion found in mining solid-liquid separation processes.

The ceramic-based design focuses on maximizing equipment durability, allowing the valve to operate safely and reliably even under the most demanding conditions, as in this mining application. The inherent wear resistance of ceramic significantly reduces both the frequency and severity of failures and component degradation. As a result, it directly lowers maintenance costs and service requirements.

This robustness was proven in practice: while conventional materials, such as elastomers used in traditional pinch valves, required maintenance every 6,000 cycles, the ceramic design extended this interval to 28,000 operating cycles. “Ceramic material withstands abrasion approximately five times longer before requiring repairs,” explains Jonathan Cerezo, Antofagasta Service Center Team Leader at Valmet Chile.

He highlights that the Neles™ E-series valve design incorporates solid ceramic structural components in critical wear areas, unlike solutions that rely only on internal coatings. According to him, this configuration enables superior resistance to extreme abrasion and ensures greater operational stability. Cerezo emphasizes that the result is not due to ceramic material alone, but rather the combination of design, materials, and application engineering.

“This is not simply a lined valve, but a solution specifically engineered for severe service, incorporating solid ceramic components and a full bore design to enable unrestricted flow. This improves operational reliability, reduces maintenance costs, and increases uptime in highly abrasive mining applications.” He also points out that the full bore design minimizes solids buildup, reduces the risk of clogging, and avoids efficiency losses - critical aspects in filtration processes and slurry handling.

Intelligent flow control supported stable operation and process optimization

Cerezo notes that the positive results were also achieved through the integration of the new valves with modern valve controllers featuring diagnostics and valve automation capabilities. These included the Neles™ NDX™ and Neles™ ND9000™ intelligent valve controllers, as well as the Stonel™ Axiom™ family of discrete valve controllers, selected as appropriate for the application.

These next-generation controllers provide embedded diagnostics and enable precise flow control. The use of advanced automation, with sensors, allows continuous monitoring. Real-time data processing ensures stable flow control, enabling continuous operation and maximizing production performance.

According to him, by applying automated flow control technologies, mining plants can improve overall performance and achieve ongoing process optimization. Another key advantage is the ability to develop customized flow control solutions tailored to mining applications - an essential factor in harsh and variable operating environments.

“Customized design ensures optimal valve performance across all mining applications, regardless of the severity of operating conditions,” concludes Jonathan Cerezo.