Issue & Importance
A mining company faced the persistent challenge of solidification with the outlet ball valves in a paste mixing system. The dead space within the cavity of conventional ball valves allowed backfill paste, similar to concrete, to harden causing severe blockages. Once solidified, the only way to resolve the issue was to either chip out the hardened paste by dismantling the piping and valves or replace them entirely. To minimize solidification, operators had to frequently cycle the valves in the open position, leading to increased wear and operational inefficiency.
The costly downtime and maintenance burden prompted the mining company to engage a renowned engineering firm specializing in backfill paste systems. Seeking a more effective solution, the engineering firm turned to Armour Valve for a reliable alternative.
Solution
After consultation with Armour Valve and our manufacturing partner SchuF, a custom rod seal actuated ram valve was selected. The engineering team, together with the hopper manufacturer, chose custom rod seal actuated ram valves designed to withstand the harsh conditions of the paste backfill process. SchuF collaborated closely with the hopper manufacturer to design a system that minimized dead space, effectively reducing or eliminating solidification events. These valves offer full flow with zero dead space at the vessel connection, preventing the paste from hardening and eliminating the frequent plugging issues experienced with the previous ball valves.
Source: SchuF
In the closed position, the SchuF Ram Flush Mounted Valves leave no dead space, reducing the need for manual rodding and ensuring consistent flow. SchuF’s ability to custom design the valves to fit the specific application requirements provided an optimal solution for reliable and efficient operation of the plant.
SchuF offers a wide range of design and sealing arrangements for every application. The modular design allows for flexibility and easy customization, while the adjustable loaded stuffing box ensures reliable sealing to the atmosphere. Each valve is equipped with exchangeable seats and benefits from SchuF’s proprietary LeakTight© sealing process for exceptional leak prevention. Additionally, a standard flushing connection is included to maintain optimal performance and prevent blockages.
Despite choosing not to include a backflush system—recommended during the customization process to flush valve inlets and clear any remaining paste downstream—the plant has experienced zero solidification issues.
Impact
Since installing the SchuF valves over four years ago, the mining company has not experienced a single solidification event, an issue they previously faced every 2-3 months.
SchuF’s dead space-free rod seal valves transformed the company’s operations. The previously clogged ball valves required several days of manual unplugging due to hardened media. The SchuF rod seal valves eliminated this problem by preventing paste solidification within the valve cavity, ensuring consistent flow and drastically reducing maintenance needs.
Robustly designed to minimize downtime, this solution not only improved operational efficiency but also delivered cost-effective and reliable backfill performance for the plant operator.
