Issue & Importance
A mining operator was experiencing frequent failures with the ball valves installed on its process water lines. The system, which relied on flow from thickener overflow, contained dirty water mixed with solids and reagents. This harsh environment caused sand and debris to accumulate inside the valves, leading to significant operational challenges.
One known issue with ball valves in slurry or solids-laden applications is that buildup over time can render them inoperable. In this case, the accumulation of sand prevented the valves from fully opening or closing, making them unreliable and unsafe. Additionally, when operators attempted to cycle the valves, the abrasive particles scratched the seats, causing leakage and reducing overall system efficiency.
As a result, the mining operator was forced to replace the ball valves in this process every 2-3 months, significantly increasing maintenance costs, unplanned downtime, and operational disruptions. With approximately 40 valves installed across the system, the ongoing need for replacements was becoming a costly and time-consuming challenge, prompting them to seek a more durable and reliable solution.
Solution
After discussing the mining operator’s challenges, Armour Valve recommended Onyx Pinch Valves as a more effective option in process water lines. Unlike ball valves, which have body cavities where sand and solids accumulate, the Onyx Pinch Valve features a flexible rubber sleeve that eliminates this issue.
With Onyx’s design, the process moves freely through the sleeve. For flow control, you simply pinch the sleeve closed, creating a tight seal. When reopened, any accumulated solids are carried downstream to the plant’s debris removal system, preventing buildup within the valve itself. This self-clearing action ensures reliable operation even in harsh, solids-laden conditions.
Source: Onyx Valves
By switching to the Onyx Pinch Valve, the mining operator could extend valve lifespan, reduce unplanned downtime, and improve overall system efficiency, making it a practical and sustainable solution for its process water challenges.
Each valve features an easily interchangeable sleeve—the only component that encounters the process fluid—minimizing wear and simplifying maintenance. With virtually unlimited design configurations, the Onyx Pinch Valve can be customized to meet specific operational needs. From different enclosures and pinching mechanisms to varied sleeve types and actuation options, the possibilities are endless.
Impact
The implementation of Onyx Pinch Valves is expected to significantly enhance operational efficiency and reliability for the mining operator. By eliminating the body cavity where sand and solids previously accumulated, the new valves minimize the risk of blockages and operational failures. This results in more consistent valve performance and safer operation.
Additionally, the self-clearing design reduces the frequency of maintenance interventions, leading to lower maintenance costs and reduced downtime. With the extended lifespan of the pinch valves, the operator anticipates a reduction in replacements, contributing to overall cost savings and improved productivity. Armour Valve confidently recommended this solution based on its reliable track record of performance in high-pressure slurry environments. We remain engaged with the operator to track results and validate the anticipated benefits, ensuring long-term reliability.
