Boosting Cyclone Spigot Durability in Gold Mining

A customer in the mining industry was experiencing a reduction in process efficiency due to wear on the cyclone spigots located at the base of the cyclone. The spigots play a critical role in directing the flow of material within the cyclone.

A cyclone is a key piece of equipment that utilises centrifugal force to separate particles based on their density. Heavier materials, such as precious minerals, are isolated from lighter waste, which is a crucial step in the mineral recovery process.

The customer, operating in the gold mining industry, required a solution to increase the lifespan of the spigots. Welding Alloys proposed a solution offering the following benefits:

• Enhanced durability: The combination of anti-wear materials ensures optimal resistance in extreme operating conditions.
• Ease of replacement: The spigots are designed to be interchangeable with existing installations, allowing for quick replacements.
• Shock protection: The polyurethane coating significantly reduces the risk of breakage compared to fully ceramic solutions.

Our Integra™ service team implemented a two-stage manufacturing process.

Stage one involved creating an interior mould using an alumina-basic ceramic mould. The ceramic lining was manufactured according to the customer’s original drawings and designed to resist intense wear caused by the high-speed friction of particles as they move through the cyclone.

Stage two involved shaping a new exterior polyurethane part around the alumina-based ceramic mould. The polyurethane provides a robust and flexible material that protects against shock. Even if dropped, it does not break.

The parts were delivered to the site to be installed and fitted by the customer. With alumina-based ceramic lining, the new spigots are expected to last 20 times longer than the original polymer components.