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Achieve maximum equipment wear resistance
and reduce costs with Slurrytech Wear Repair
Compound (WRC). WRC is an epoxy wear patch
system designed to create value and offer
safe solutions, WRC has been extensively
field tested and is a proven superior wear
resistant material. It consists of a
trowlable ceramic filled polymer with a
technologically advanced formulation that
delivers:
• Maximum wear
resistance and temperature performance in a
wide variety of wet and dry applications
• User-friendly, odour-free, non-hazardous,
non-corrosive materials for safe shipping,
storing, and handling
• Reduced costs and increased maintenance
savings due to reduced erosion and decreased
downtime
• Ability to be formulated for specific wear
applications and environments
• Rapid curing system within 1 to 2 hours at
room temperature; as quick as 15 minutes at
elevated temperatures
Maximum
Protection...
Created, tested
and perfected in the lab and field WRC
systems were designed to resist wear and
abrasion for extended periods of time in
both wet and dry applications and in a wide
range of varying temperature applications.
Our WRC range utilises 2 blends of
materials:
• WRC-1C, Coarse –
A blend of large and smaller sized SiC in a
non-sagging Kevlar epoxy blend matrix.
• WRC-1S, Smooth – A blend of smaller SiC
particles forming a smooth trowelable
compound
To achieve this
maximum level of durability, the process
begins with a mixture of ultra-high loading
levels of silicon carbide (SiC) particles,
DuPont Kevlar® fibres and state-of-the-art
epoxy systems. This unique non-sagging
patching system provides the ultimate wear
resistant solution.
Wear Solutions...
WRC is designed
to maximize equipment lifetime while
reducing overall costs. Through advanced
technology and flexibility to perform
customized applications, WRC can meet the
demands of a large variety of specific wear
environments. With WRC, equipment erosion
and corrosion is reduced, resulting in
increased maintenance savings, reduced
overall repair costs, and decreased
downtime. WRC is designed not only to
maximize equipment lifetime and increase
maintenance savings, it is formulated with
the end-user in mind. In a carefully
controlled, cure-staged process, WRC is
created as an odour-free, non-hazardous and
non-corrosive epoxy system. WRC offers a
safe and effective wear resistant solution
for today’s aggressive environments.
1. WRC-1C-
2. Nordbak – Fine
Grit
3. Belzona
4. Nordbak - Course
Grit
As can be seen from the above slurry pin
test, our SiC filled epoxy has a much better
wear resistance.
The pin test is designed to
spin the pin in a water and sand slurry at a
speed to create a 10 meter a second face
velocity.
WRC stands
alone in performance for cost value with a
wear life ratio up to six times that of
competitors products. Easy to use and apply,
inert and safe to use WRC sets a new
standard in the field of wear part repairs.
The graphs
below show the exceptional performance of
the WRC product.
Product Packaging...
|
Part No. |
Description |
Comments |
|
WRC-4C |
Wear Repair Compound Coarse
(4 lt - 6 kg) |
4 lt Localised wear repair |
|
WRC-4S |
Wear Repair Compound Smooth
(4 lt - 6 kg) |
4 lt Broad application repair |
|
WRC-1C |
Wear Repair Compound Coarse
(1 lt - 1.5 kg) |
1 lt Localised wear repair |
|
WRC-1S |
Wear Repair Compound Smooth
(1 lt - 1.5 kg) |
1 lt Broad application repair |
|
WRCAPS-0.5 |
Active Polymer System Primer
(0.5 lt) |
Use on alloy parts repairs |
|
SG0020-20M |
Silicon Carbide Grit 20 Mesh ~
1.0mm (0.5kg) |
Used for super loading NS |
Pumps, Cyclones, Hoppers, Chutes, Pipes....
Wear Life Solutions...
WRC
can assist in extending the life cycle of
your current abrasive duty pumps. Based on
utilising OEM or even others parts in
conjunction with WRC repair compounds along
with our thorough understanding of slurry
wear mechanics Slurrytech have achieve
significant parts cost reductions.
By using parts with a longer initial wear
life while maintaining existing maintenance
cycles allows for them to be damage repaired
with WRC or prior to catastrophic failure.
Holing through to re-enforcements is typical
for elastomer impellers and parts and
generally leads to a catastrophic parts
failure with chunking out of material.
Actual Scenario...
Location: Mineral Sand operation in Western
Australia.
Equipment: 10/8G-AH Warman slurry pump.
Materials: Polyurethane liners and impeller.
Duty: Heavy sand loading to 45% c/w.
Impeller Life: 20 weeks
Maintenance Cycle: 20 weeks
OBJECTIVES
> Aim to remove impeller and throatbush at
20 week cycle prior to catastrophic failure.
> Rebuild worn areas of impeller and
matching components using WRC NS reinforced
rebuild material.
> Replace into duty with goal to run for
same maintenance cycle.
> Repeat cycle as many times as possible for
greater cost effectiveness.
OUTCOMES
> WRC impeller repair achieved 20 week
maintenance cycle.
> Newly worn locations rebuilt with WRC.
> Cycle will be repeated indefinitely until
impeller is deemed unfit for service.
BENEFITS
> Reduced waste and environmental impact
through equipment recycling.
> Reduced cost as impeller will be used
through multiple cycles.
> Results and benefits can be applied across
plant for additional savings.
Cost
Implications...
Historically it was not cost effective to
consider parts rebuild with repair compounds
as no available product was able to match
and / or exceed the parent material wear
life. Our WRC range of products have
answered this problem with their SiC and
Aramid fibre infused epoxy based repair
compounds.
Now you can expect to achieve a similar or
better result to parent material by using
WRC. With Patented compositions our products
mimic microstructures of hard wearing
carbides in a retaining matrix. With WRC the
matrix consists of epoxy that is Aramid
fibre reinforced with a matrix of SiC
particles specific to the duty and particle
size distribution.
Cut, gouge and tear mechanics of wear are
retarded significantly. As abrasive solids
impinge on the surface of our repair
materials they are retarded in their cutting
through the high concentration of SiC
particles and Aramid fibres which knit the
material together.
Used in high wear zones of liners, pipes,
screens, mills etc. WRC can significantly
reduce the life cost of your abrasive duty
machinery. The following Cost Implication
Example is based on approximate costs for a
10/8 size slurry pumps main failure
components.
PARTS REPAIR v's REPLACEMENT
Application Techniques.
WRC-1C can be modified in application
to suit the specifics of component repair
and duty conditions.
This is achieved through "Super loading" of
the compound with additional SiC grit to
achieve a higher wear material ratio.
The epoxy phase with it's Kevlar reinforcing
can withstand higher loading in areas that
are less prone to mechanical stress and
forces, typical areas include:
Pump Parts - Side walls, volutes,
throatbushes and frame plate liner inserts.
Impellers / Mixer Blades / Propellers - Eye
and rear shroud can be super loaded. O.D's
can have higher loadings depending on tip
speeds, below 28 m/s is a nominal
recommendation, this equates to material
limitations for elastomer parts before
molecular breakdown effects the bond
integrity.
Cyclones / chutes / launders / tanks / pipes
- All parts can be super loaded for low
angle solids impingement. High angle
impingement should be incrementally trialed
to achieve the highest loading possible
without suffering from fracturing and
breakout. The less epoxy Kevlar binder the
lower the fracture toughness and resistance
to impact damage from larger solids.
WRC-1S can also be super loaded
specific to application requirements. SC
contains high concentrations of smaller SiC
particles and is predominantly used for
covering larger surface areas on softer
wearing applications.
Typical examples are:
Water pump parts on contaminated duties to
extend parts life.
Cyclone parts rebuild, followed by
application of NS finish coat for known wear
zones.
Slurry pumps cast iron Cover and Frame
plates, coating of inside of parts to resist
wear due to liner blow out.
CURING, curing is achieved through
exothermic reaction (heat generating
chemical reaction) of the epoxy phase, this
can be enhanced and accelerated through the
use of a heat gun on a low temperature
setting for small repairs or an industrial
heater below 55 deg C for larger areas.
Curing time is a function of ambient
temperature and component temperature,
accelerated heating can reduce curing time
to 20 mins for urgent repair jobs. All
compounds can be used on Alloy, Rubber and
Polyurethane materials to effect long
lasting repairs. Poly and Alloy benefit
greatly from the use of the APS primer
system which increases the bond integrity.
For alloy parts where possible it is
recommended to preheat the local repair area
so it does not act as a heat sink.
Field Results, Proven in Service...
2007 - 2008 Coal
Washing Plant
Problem: A schedule 30 material discharge
elbow made of carbon steel was wearing out
in 30 - 40 days.
Solution: The carbon steel elbow was coated
inside with a 3⁄4" layer of WRC NS and
smoothed with water to give an even, smooth
surface.
Result: After 4 months of operation, the
elbow did not show signs of wear. Client
saved approximately $10,000 in downtime
costs.
2007 - 2008 Iron
Ore Processing Plant
Problem: Magnetic separators, guides, pipes,
and steel conveyors need regular epoxy
patching due to wet wear conditions. The
main issues are cure time and safety with
performance over competitive epoxies being
secondary considerations.
Solution: Installed WRC NS on magnetic
separators, guide trays, and transfer pipes.
Result: Workers were pleased by the lack of
odour and the 3 - 4 hour cure times. In
addition, these mines will use industrial
hot air guns and torches for curing. WRC can
be cured with an 850 0 F hot air gun in less
than 10 minutes.
2008 - 2009
Silica Sands Plants
Problem: Attrition mill paddles were wearing
out within 30 days. The prior protective layer
had been Tungsten carbide.
Solution: In an emergency, the plant shut
down due to paddle wear. WRC NS used as a
“temporary” quick fix repair until the next
scheduled shut down.
Result: WRC lasted for 90 days with three
times the performance of Tungsten carbide
realized at a fraction of the cost.
2007 - Silica
Sands Plants
Problem: Attrition and wear of rubber slurry
pump impeller in 15 weeks.
Solution: Modified application of WRC NS
with "Super Loading" of SiC particles.
Result: WRC lasted for 15 weeks with ~10 to
15% wear compared to parent material.
Impeller placed back into service for
another 15 week run with a target to repair
and reuse for 3 to 4 maintenance cycles.
Additional benefits are reduced
environmental impact through reuse of parent
part.
2007 - 2009 - Mineral
Sands Plants
Problem: Attrition and wear of polyurethane
slurry pump impeller in 20 weeks.
Solution: Modified application of WRC NS
with "Super Loading" of SiC particles.
Result: WRC lasted for 20 week cycle with ~
50% wear compared to parent material.
Impeller repaired with WRC NS placed back
into service for another 20 week run with a
target to repair and reuse for 3 to 4
maintenance cycles. Additional benefits are
reduced environmental impact through reuse
of parent part. Successful application can
be applied across plant for additional
benefits. |
