The mining industry is one of the most demanding environments for equipment and materials, requiring solutions that can withstand extreme conditions while ensuring safety and efficiency. For a Chilean open-pit mine producing 75,000 tonnes of copper annually, finding the right sealing solution was a critical challenge. This case study explores how Durlon® 9000, a high-performance sealing material, addressed these challenges and provided significant benefits.
The Challenge
In the mining sector, particularly in processes like heap leaching, choosing the correct materials is vital to maintaining operational efficiency and safety. Heap leaching is used to separate copper from other by-products; however, it typically achieves only a 60-70% mineral recovery rate. Moreover, the process involves highly aggressive chemicals, such as 98% sulfuric acid, which can easily degrade incompatible gasket materials, leading to joint leaks. Such leaks pose serious risks to worker safety, environmental health, and can result in significant financial losses due to downtime, liability, and product loss.
The Chilean mine needed a cost-effective and durable sealing solution that could withstand these harsh conditions without compromising safety or efficiency.
The Solution: Durlon® 9000
After careful consideration and collaboration with the mine’s engineers, Durlon® 9000 was selected for its exceptional compatibility with sulfuric acid and its ability to endure the challenging leaching conditions. Durlon® 9000, a PTFE-based gasket material, has a proven track record of high sealability, making it an ideal choice for environments where chemical resistance and durability are paramount.
The Benefits
The decision to switch to Durlon® 9000 provided the mine with several key benefits:
- Reduced Joint Leakage: By replacing their old ring gaskets with Durlon® 9000, the mine was able to significantly reduce joint leakage, thereby minimizing fluid contamination and increasing mineral recovery.
- Increased Safety and Environmental Protection: The improved sealing capability helped prevent leaks of hazardous materials, thereby protecting workers and the environment from potential exposure to aggressive chemicals.
- Cost-Effectiveness: The durability and reliability of Durlon® 9000 reduced the need for frequent replacements and maintenance, translating to cost savings in both the short and long term.
The case of the Chilean open-pit mine demonstrates how choosing the right sealing material can make a substantial difference in both operational efficiency and safety. Durlon® 9000 provided a robust and reliable solution that not only met the mine’s stringent requirements but also contributed to its overall sustainability and cost-efficiency goals. For industries facing similar challenges, Durlon® 9000 offers a proven path forward.
For more information about Durlon® 9000 and its applications, visit Durlon Sealing Solutions.