Wear-Resistant Cyclone
Produr offers a wide range of wear-resistant materials specifically designed for your cyclone separators.
Based on dimensioned drawings or on-site measurements carried out by our teams, we redesign and manufacture new cyclones in abrasion resistant steel or ceramic-lined.
We can modify their internal geometry to ensure smoother slurry flow and reduce wear, while maintaining the same inlet and outlet flow rates and velocities.
Our solutions take into account your requirements, wear mechanisms and the specific characteristics of your equipment:
- Equipment characteristics remain unchanged
- Measurements including positioning and dimensions of the supports
- Installation in place of existing units using adaptation flanges
Wear-resistant materials for your cyclones
The use of advanced technical ceramics adapted to each cyclone zone allows optimization of the overall service life of the equipment.
- The ceramic Aldur® 240 is used for the head and the upper sections of the cone.
- The ceramic Durhart® 200 is used for the lower sections of the cone.
- Our overlay plate Duraplate® can in some cases be used for the cyclone chimney.
The components are monolithic, therefore there is no risk of lining detachment, as it is secured within its steel shell using a specific mortar.
In addition, we are able to combine these elements to optimize costs or extend equipment service life.
Case Study: Wear-Resistant Cyclone
CASE STUDY
Manufacture of a cyclone cone in Duraplate® D31T
Subject to premature wear, a recycling cyclone cone was completely remanufactured by PRODUR in Duraplate® D31T (thickness 6+4 mm).
Thanks to its homogeneous drawn weld beads, this overlay plate provides high resistance to direct abrasion and optimized installation. A robust solution to sustainably improve the reliability of a critical area.
CASE STUDY
Reliability improvement of a magnetic separation cyclone
Faced with severe wear observed on the dust extraction systems of a magnetic separation unit, WA PRODUR designed a complete solution:
- DURAPLATE® D31T for the chimney
- ALDUR® 240 for the head
- DURHART® 200 for the cones
Proven technical materials adapted to abrasive flows and intense mechanical stresses.
Result: improved durability, easier assembly and reduced maintenance.
CASE STUDY
Reliability improvement of a cyclone distributor
On this mineral processing line, the distributor feeds hydrocyclones with a highly abrasive slurry. The previous rubber-lined model was wearing out too quickly.
We designed a reinforced version in Durhart® 200, a molded technical ceramic with a thickness of 25 mm.
Result:
Service life multiplied by 3
Optimized geometry to reduce tangential abrasion
No risk of tile detachment
CASE STUDY
Reliability improvement of a cyclone cone
Faced with premature wear of cyclone cones in a steel sintering installation, PRODUR proposed a complete redesign of the component with an internal lining in DURHART® 200.
This electro-fused ceramic, combined with an abrasion resistant steel shell, made it possible to increase the service life by more than 10 times and significantly reduce maintenance-related downtime.
CASE STUDY
Reliability improvement of a cyclone
In a chemical processing installation, PRODUR designed a cone + cyclone head assembly reaching nearly 4 meters in height, with a clear objective: extending equipment service life in the face of intense abrasion.
The internal lining was made in DURHART® 200, an electro-fused ceramic known for its exceptional abrasion resistance.
Thanks to a specific design (adapted thicknesses, flanges, acid-resistant mortar…), the integration of the lining is optimized despite the height of the cyclone.
Need advice, a wear audit, or a quotation?
A requirement, a project, or simply the need to review possible improvements to address wear issues? Benefit from our expertise.
Contact our team of specialists by filling out the contact form.
We are ready to take on your next challenges.