Innovative Composites & Industrial Coatings
Repair Protect Upgrade
Case Study: Single Stage End Suction Pump Repair.
Copper Mine.
Single Stage End Suction Pump Repair: Copper Mine
At South African copper mine, a single-stage end-suction pump faced severe abrasion challenges. The pump was tasked with handling process water containing trace amounts of sulfuric acid and high concentrations of copper particulates, which accelerated wear on the cast components. This frequent wear necessitated regular maintenance, disrupting operations. Seeking a more durable solution, the plant manager specifically requested a repair for the single-stage end-suction pump that could withstand the harsh conditions and provide a service life of at least six months.
Resimac’s Single Stage End Suction Pump Repair Solution at a Copper Mine
- Grit blasted to ensure proper adhesion.
- Two coats of 202 Ceramic Repair Fluid applied to protect components exposed to process fluids.
Application Details: Single Stage End Suction Pump Repair. Copper Mine.
The end-suction pump’s cast surfaces underwent grit blasting to Sa2.5 in accordance with ISO 8504-1 and SSPC SP-10 (NACE 2 Near White Metal). This process achieved a minimum 75-micron angular profile, ensuring the complete removal of corrosion, old coatings, and surface contaminants, and creating an optimal surface for maximum coating adhesion.
Two coats of Resimac 202 Ceramic Repair Fluid were applied with brushes, each coat having a nominal thickness of 300–350 microns. All internal components exposed to process water and abrasive particulates were meticulously coated, ensuring comprehensive protection in critical areas such as impeller surfaces, pump volutes, and casings.
The high-performance ceramic coating delivers exceptional abrasion and corrosion resistance, providing durable protection against the harsh operating conditions of the mining facility.
Results and Benefits of Resimac’s Single Stage End Suction Pump Repair Solution at a Copper Mine:
The application of Resimac 202 Ceramic Repair Fluid delivered robust protection for the pump, enabling it to endure the erosive and abrasive conditions caused by sulfuric acid and copper particulates. This repair of the single-stage end-suction pump surpassed the general manager’s expectations for durability, providing a cost-effective solution that significantly minimized the need for frequent replacements.
The success of this application prompted the coating of additional pumps, further enhancing the mine’s maintenance strategy and ensuring long-term operational efficiency.
