IRON ORE PORT FACILITY

PRECIPITATOR
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HISTORY TITLE>
AGITATOR BLADES
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size 10 x 13.33
SUMMARY
PRECIPITATOR AGITATOR BLADES
PRODUCT
: ARC S3 & ARC 855 HT
INDUSTRY
: Alumina Refinery
EQUIPMENT
: Precipitator Agitator Blades
LOCATION
: WA, Australia.
DATE
: 28th January 2013
SUMMARY
: The blades were badly damaged due to abrasion and
chemical attack from hydrate slurry in the precipitators
with 15 – 20% caustic operating between 75° - 100°C.
ROI
: These blades have been in service for 3 Years and are
showing zero failure points and virtually no wear.
1800 352 228
WWW.IMATECH.COM.AU
PROBLEM DESCRIPTION
• The blades were previously coated with both Nickel Chromium Alloy
and Chromium Oxide-Silica composites applied by plasma metal
spraying.
• They were lasting approx. 5 years however repairs after this period
required them to be off site for 3 – 4 weeks at a cost of approx.
AU$30,000.00.
1800 352 228
WWW.IMATECH.COM.AU
SOLUTION
• The customer was looking for a repair system that could still give
a similar service life but be easier & quicker to repair.
• Imatech offered a repair solution involving ARC composites which
shortened the repair period to 10 days, at a third of the traditional repair
cost.
Process:• Plates were welded inside the large holes to close them.
• The entire surface of the blades were abrasive blasted.
• Smaller holes were filled with ARC BX1 & shaped.
• The leading edges & tips of the Blades were then lined with 3mm
of ARC MX3.
• Finally the entire blade surface was lined with ARC 855 HT.
1800 352 228
WWW.IMATECH.COM.AU
SOLUTION
STAGE 1:- Repair Process
Welding Metal Plates to fill
the large holes
1800 352 228
WWW.IMATECH.COM.AU
SOLUTION
STAGE 2:- Repair Process
All holes are filled & shaped
with ARC BX1
1800 352 228
WWW.IMATECH.COM.AU
SOLUTION
Stage 3:- Coating
Leading Edges & Tips
are coated with
ARC MX3
at a thickness of 3mm
1800 352 228
WWW.IMATECH.COM.AU
SOLUTION
Final stage:- Top Coat
The Blades were “brush blasted” & coated
with 2 X Coats of ARC 855 HT
1800 352 228
WWW.IMATECH.COM.AU
SOLUTION
Finished Product
The whole job was completed in 9 days
including post curing for 6 hrs @ 130°C
to cure both products.
Final Cost was a “third” of what it
would have cost.
1800 352 228
WWW.IMATECH.COM.AU
RESULTS
DECEMBER, 2012
Top view into the precipitator.
Exactly 3 years in service,
All 3 blades show virtually
No wear!!
1800 352 228
WWW.IMATECH.COM.AU
RESULTS
After 3 Years Continuous Service, there is only a slight build-up of product on the
blades.
The ARC 855 HT (top coat) is still showing a relatively good “gloss” level.
Based on these results, there is no reason why this ARC Coating will not exceed
the required 5 years…and more.
1800 352 228
WWW.IMATECH.COM.AU
RESULTS
Since this application was done, ARC 855 HT has been replaced by ARC HT-T
which has at least 20% higher Ceramic Loading than the ARC 855 HT which
will further increase the lining service life.
At ⅓ of the cost & half the “turn around” time, it makes ARC an excellent 1st
Option for future Repairs and lining of NEW Blades.
1800 352 228
WWW.IMATECH.COM.AU
CONTACT US
Let us help you find out how our high temperature ARC
ceramic coatings can improve your operations, and save you
time and money.
Toll free
International
Email
Website
1800 352 228
WWW.IMATECH.COM.AU
: 1800 352 228
: +61 2 8853 3000
: [email protected]
: www.imatech.com.au