Fertiliser plants face significant wear-related problems in the form of abrasion, corrosion, and impact, where the fertiliser stars, in particular, are impacted. Wear of fertiliser stars can drastically decrease the efficiency of overall operations and eventually cause the plants to halt work, thereby increasing plant downtime and costs.
At Welding Alloys, we offer extensive knowledge of wear problems, and we can develop tailored solutions to address specific wear problems within fertiliser plants.
When we were approached by an Argentinian customer operating in the fertiliser industry, they told us that they were referred to us by one of our existing customers because of our technical expertise, which was a great compliment.
After the initial session to understand the customer requirements and challenges, our technical experts in Argentina conducted a full assessment on the star crusher. Our team determined that the working environment was highly corrosive due to the star crusher being subjected to sulphuric acid diluted with water – pH1 and fluorosis acid diluted with water – pH3. This was causing the arms of the star to deteriorate rapidly over only a 7 – 10-day period of daily use, which was extreme but by no means the worst level of corrosion our teams have encountered.
After a thorough analysis by our technical teams, they documented their findings and proposed two viable solutions for dealing with the excessive wear experienced on the crusher star. The first of which was also proposed by the customer during our first meeting, when they requested that we simply repair and protect the current star crusher using one of our specially manufactured wires.