Alumina refineries operate in environments of high abrasion and require robust solutions to keep their systems running efficiently. One common challenge is maximising the wear life of spools to reduce frequent changeouts that disrupt production.
Challenges
In abrasive slurry and material handling applications, plain steel spools suffer from rapid wear, leading to repeated maintenance and higher costs. Extending the wear life is critical to achieving longer operational uptime, fewer shutdowns, and greater output for refinery operators.
Solutions
Castech Solutions delivered an innovative upgrade by lining spools with High Chrome White Iron. This alloy is renowned for superior abrasion and impact resistance in high-demand environments. The inner lining of chrome iron guards against sliding and impact wear, while the outer mild steel cladding ensures the structural integrity needed for high-pressure applications.
Chrome White Iron liners offer wear life up to 4 to 6 times longer than conventional steel spools.
Liner and spool assemblies are designed for modular replacement, meaning only worn liners require renewal, not the entire spool.
Key outcomes & benefits
8 months since installation, these chrome iron lined spools have shown minimal wear in service at a major alumina refinery. Operators expect a lifespan up to 6 times longer than standard steel options, translating into major operational and financial advantages.
Tangible benefits include:
Reduced frequency of maintenance and shutdowns.
Increased plant uptime and productivity.
Reusable outer steel spool, minimising replacement costs and environmental impact.
Significant cost savings through less frequent part replacement and less downtime.
