Ceramic Valve Solutions for Mineral Slurry Handling
Reliable flow control for high-solids, abrasive, corrosive and scaling slurry in mineral processing, tailings transport and mine backfilling systems
Wear-resistant and corrosion-resistant ceramic valve solutions for high-solids mineral slurry, tailings transport and high-pressure mine backfilling systems
Slurry Transportation
Slurry Transportation Systems · Paste Backfill Systems
Key Industries
- Non-ferrous metal mining
- Lithium mining
- Ferrous metal mining
- Other mining applications
Operating Conditions
Slurry transportation systems handle highly concentrated paste containing large quantities of solid mineral particles. In wet-process mining, the medium may be acidic or alkaline and is continuously subjected to particle erosion and abrasive wear
The slurry is pumped through pipelines under fluctuating pressure. Its high viscosity makes it prone to scaling, sedimentation and valve sticking. Although the process generally operates at ambient temperature, valves must withstand the combined challenges of abrasion, corrosion, blockage and crystallization. Ceramic valves are particularly well suited to these severe conditions
| Parameter | Operating Condition | Additional Information |
|---|---|---|
| Slurry solids content | 65-75% | Typical paste-backfill range; may reach 80% |
| Operating temperature | Ambient, 10-45°C | No high-temperature service |
| Operating pressure | Atmospheric pressure to 8.0 MPa | Low pressure at thickener underflow; high and strongly fluctuating pressure at the backfill-pump outlet |
| pH range | 2-12 | Wet tailings from non-ferrous mining are often acidic; iron-ore and coal-mine slurries are generally mildly alkaline |
| Solid particles | Fine tailings; maximum particle size ≤5 mm | Particles continuously erode and abrade the valve’s wetted components |
Special Characteristics of the Operating Conditions
High Solids Content and Severe Particle Erosion
Mineral slurry typically contains 65-75% solids, including large quantities of hard tailings particles. Under high-velocity conveying conditions, these particles continuously erode and abrade the valve. Seats, balls and other wetted flow-path components wear rapidly, resulting in frequent valve replacement
Wide pH Range with Both Acidic and Alkaline Corrosion
Non-ferrous mining slurries may range from pH 2 to 12. The media include both acidic leached tailings and alkaline slurries produced by precipitation processes. Alternating acidic and alkaline conditions can cause pitting and galvanic corrosion in metal valve components
Highly Viscous Paste Prone to Scaling, Sedimentation and Sticking
Paste slurry is highly viscous and may contain cementitious additives and mineral sand. These materials readily precipitate, crystallize and adhere inside valve cavities, on sealing surfaces and within flow passages, causing blockage, valve sticking and eventual functional failure
Strong Pressure Pulsations and Impact Loading
Paste-backfill piston pumps typically operate over a pressure range of 0-8 MPa. Significant pressure pulsations and hydraulic impact place demanding requirements on valve strength, pressure resistance and fatigue life
Sedimentation Risk Requires an Anti-Blockage Design
During shutdowns, solid particles readily settle and compact inside valve cavities and dead zones. Conventional valves with internal pockets are highly susceptible to blockage. The valve therefore requires a smooth, straight-through flow path with no cavities or dead spaces
Five Major Process Challenges in Slurry Transportation
Severe Erosion from High-Solids Slurry
Tailings paste contains 65-75% solids, including large quantities of fine, hard tailings particles. Under high-velocity conveying conditions, these particles continuously erode sealing surfaces and internal flow components. Metal internals deteriorate rapidly, causing frequent failures and replacement and persistently high spare-parts and maintenance costs
Corrosion Across a Wide pH Range
Non-ferrous tailings may range from pH 2 to 12, involving both acidic tailings and alkaline cement-based slurry. Alternating acidic and alkaline conditions cause pitting and galvanic corrosion, resulting in sealing-surface and valve-trim failure, increased internal leakage and shorter service life
Scaling and Valve-Sticking Risks
Paste slurry is highly viscous. Mineral salts and cementitious materials readily precipitate, crystallize and adhere inside valve cavities and flow passages. This can cause valve-trim sticking, reduced flow area, actuator malfunction and loss of control accuracy, threatening the stable operation of the backfill system
Sedimentation Causing Blockage and Shutdowns
During shutdowns, solid tailings particles readily settle and compact inside valve cavities and dead zones, forming hard deposits that obstruct the flow path and cause interruption. Conventional control valves contain numerous dead spaces and are particularly susceptible to unplanned shutdowns, disrupting continuous backfilling operations
Pressure Pulsations from Piston Pumps
Paste-backfill piston-pump outlets typically operate at pressures from atmospheric pressure up to 8 MPa. Severe pressure pulsations and repeated alternating loads can cause sealing leakage and fatigue damage to valve components. Valves therefore require excellent impact resistance, sealing reliability and fatigue strength
Ceramic Valves Precisely Address Five Key Challenges in Slurry Transportation and Backfill
Corrosion Across a Wide pH Range
Exceptional corrosion resistance: Engineered ceramics provide excellent chemical stability across a broad pH 2-12 range. They withstand both acidic tailings and alkaline cement-based slurry, resist alternating acid-alkali corrosion, prevent valve-trim and sealing-surface failure, and eliminate the risk of process-medium leakage
Erosion from High-Solids Slurry
Outstanding wear resistance: Alumina ceramics offer exceptional hardness and resist tailings-particle erosion far more effectively than alloy metals. In paste slurries containing 65-75% solids, ceramic valves substantially extend service life, reduce spare-part replacement frequency and lower backfill-system maintenance costs
Scaling, Crystallization and Valve Sticking
Smooth, anti-fouling surfaces: Dense, smooth ceramic surfaces resist the adhesion of cementitious agglomerates and mineral-salt crystals. This reduces scaling within valve cavities, prevents valve-trim sticking, maintains responsive operation and preserves accurate flow control throughout the backfill pipeline
Sedimentation Causing Blockage and Shutdowns
Optimized anti-blockage flow path: A straight-through, cavity-free flow-path design prevents material buildup and tailings sediment accumulation. Solid particles are less likely to compact inside the valve during shutdowns, helping prevent blockage and process interruption while supporting continuous backfilling operations
Pressure Pulsations from Piston Pumps
Reliable resistance to alternating-pressure impact: Ceramic components provide excellent fatigue resistance under the 0-8 MPa pressure pulsations generated by paste-backfill piston pumps. They withstand repeated pressure cycling, reduce fatigue damage to sealing components and improve overall sealing reliability in high-pressure slurry-conveying systems
Case Study
Mineral Slurry Handling: site photographs
End Users
| End User | Application | Valve |
|---|---|---|
| Shandong Iron & Steel Group Laiwu Iron Mine Co., Ltd. | Paste backfill | DN80 ceramic control valve |
| Anhui Longqiao Mining Co., Ltd. | Tailings backfill | DN150 ceramic control valve |
| Jiangxi Pansen New Materials Co., Ltd. | Slurry transportation system | DN50 ceramic ball valve |
| Anhui Tongling Tianmashan Gold Mining Co., Ltd. | Paste backfill | DN100 ceramic control valve |
| Qingdao Sanyi Metallurgical Materials Co., Ltd. | Slurry transportation system | DN125 ceramic on/off valve |
| Zhaojin Mining, Jinling Gold Mine | Tailings backfill | DN80 ceramic control valve |
| Tongling Group Dunhuang Tower Mining Co., Ltd. | Slurry transportation system | DN50/DN80 ceramic control valves |
| Shandong Gold Mining, Jiaojia Gold Mine | Tailings backfill | DN100/DN150 ceramic control valves |
| Inner Mongolia Abaga Banner Jindi Molybdenum Co., Ltd. | Tailings backfill | DN65/DN125 ceramic control valves |
| Luzhong Metallurgical Mining Group Co., Ltd. | Tailings backfill | DN100 ceramic control valve |
Operating Case
At the site, an electrically actuated ceramic ball valve transfers 750 t of fine sand and water at a concentration of 60%-72% from the sand silo to a mixer by gravity. Cement is then added and mixed with the slurry
A ceramic control valve installed at the mixer outlet regulates the discharge of the 80 m³ batch before the slurry is conveyed to an underground backfill zone approximately 300 m below ground
- Valve: DN100 electrically actuated ceramic control ball valve
- Commissioned: January 2011
- Actual service life: Control valve ≥8 years
Commonly Used Products
FCCV1
Standard Ceramic Ball Valve
The FCCV1 series is the standard model in the ceramic ball-valve range. It is designed for highly corrosive and severely abrasive service at temperatures up to 180°C and differential pressures up to 2.0 MPa
- Wide sealing surfaces and scraper-type valve seats provide reliable shutoff and extended service life
- The ball and valve-seat sealing surfaces are match-lapped to ensure tight sealing
- The stuffing box incorporates live loading that maintains a constant packing load even after substantial wear, extending packing service life
- The symmetrical valve design provides bidirectional sealing with no flow-direction restrictions
- Wide ceramic flange-sealing surfaces protect the metal flanges from erosion and corrosion by the process medium
ELCV
Economical Ceramic Ball Valve
The ELCV uses essentially the same basic structural design as the FCCV1 but does not include a top mounting platform. Materials can be selected flexibly according to the operating conditions, providing a more economical ceramic-valve solution, although overall reliability is slightly lower than that of the FCCV1
| Parameter | Specification |
|---|---|
| Valve design | Floating-ball construction |
| Flange standards | ASME B16.5 / HG / DIN / JIS |
| Pressure rating | PN10-PN50 / ASME Class 150-300 |
| Operating temperature | −40°C to 180°C |
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