In demanding industrial environments where aggressive chemicals and elevated process risks are common, selecting the right sealing material is essential. Copper foundries must address both safety and efficiency when managing corrosive substances such as high-purity sulfuric acid. This case study explores how a major South American copper foundry integrated Durlon® 9000 gasket material into its acid plant to improve operational safety, meet environmental goals, and reduce costly downtime.
Addressing Critical Sealing Challenges in Copper Smelting
The copper foundry featured in this study processes over 1,160,000 tonnes of copper concentrate annually. In addition to copper production, its smelting process yields high-purity sulfuric acid as a by-product. Handling this substance requires high-performance sealing materials that resist chemical degradation and mechanical failure.
The consequences of improper sealing in this environment are severe. Equipment failure due to incompatible or underperforming gasket materials could result in toxic leaks, emergency shutdowns, and significant safety hazards for personnel and surrounding communities. Additionally, the plant needed to reduce sulfur dioxide emissions and particulate matter to maintain regulatory compliance and advance its sustainability objectives.
Durlon® 9000: A Proven Sealing Solution
To meet these challenges, the facility selected Durlon® 9000 for its acid plant applications. This PTFE-based gasket material is engineered for superior chemical compatibility and thermal stability, particularly in systems that involve aggressive media like concentrated sulfuric acid.
Durlon® 9000 is recognized for its low leak rates and durability across a wide temperature and pressure range. In this case, it was installed in piping systems operating between 10°C and 110°C and pressures ranging from 20 to 50 psi. Its proven performance allowed the facility to confidently address safety and emissions challenges without the need for further material testing or substitution.
Key Benefits Realized by the Foundry
Improved Worker and Equipment Safety
Durlon® 9000 significantly reduced the risk of chemical leaks and associated safety incidents. Its ability to maintain seal integrity in corrosive and high-pressure environments helped protect workers and maintain safe operating conditions.
Support for Emissions Control and Environmental Standards
Compliance with TA Luft, a respected European air pollution control standard, made Durlon® 9000 a strategic choice for reducing fugitive emissions. This helped the facility align with internal sustainability targets and regional environmental regulations.
Greater Operational Efficiency
The gasket’s mechanical stability and chemical resistance minimized the need for frequent maintenance and replacement. This allowed the facility to maintain consistent production, reduce unscheduled downtime, and allocate resources more efficiently.
Sustainability Integration
By minimizing emissions and material waste, Durlon® 9000 helped the foundry support its broader sustainability goals. Reduced risk of contamination and fewer gasket failures contributed to cleaner operations and a lower environmental impact.
A Smarter Approach to Sealing in Harsh Conditions
The success of Durlon® 9000 in this copper foundry reinforces the importance of using application-specific gasket materials. Its superior sealing capabilities and broad chemical resistance profile make it an ideal choice for industries that demand reliability, safety, and compliance under challenging conditions.
For copper processing operations, chemical plants, and similar industries, Durlon® 9000 offers a clear advantage in performance and lifecycle value. Its track record in the field demonstrates the long-term benefits of investing in high-quality sealing solutions that support both operational continuity and environmental responsibility.
To learn more about Durlon® 9000 and its applications, visit Durlon Sealing Solutions.