VALVE MAGAZINE Summer 2024

MINING CASE STUDY

valve types. However, this test case demonstrated that for the speci c severely abrasive control applications in this mining application, the right approach is an engineered valve designed speci cally for the process conditions to ensure proper control while minimizing turbulence and centering the ow.

the uid through the valve. An iterative approach using Computational Fluid Dynamics (CFD) simulations was employed to study the velocity gradients through the valve at di erent ow conditions and analyze ow parameters such as turbulence, eddies and areas of ow recircula tion that could create excessive erosion damage to valve components. This design approach allowed the engineering team to minimize unwanted turbulence and evaluate valve performance in all throttling conditions while carefully monitoring the discharge jet and many other variables to predict valve performance in the eld. Another crucial design step in the custom engineering of a valve for this speci c abrasive ow environment was the dedicated approach to streamline ow components. This nal step of the design philosophy required selecting materials appropriate for the given application in terms of corrosion, temperature, pressure limitations and espe cially abrasion. In some cases, a proprietary composition of carbide was selected to balance toughness and strength with abrasion resistance, as these valves must function in some of the harshest ow environments with large solids and high-velocity tailings uids. Following the above described design and custom engi neering philosophy, the reliable and predictable operation of severe service control valves designed to handle tailings discharge has been practically demonstrated at NewCrest. In many mining applications, end users are reluctant to use control valves for throttling high percentage solids tailings uids, as they have proven to be di cult for most control

ABOUT THE AUTHORS

Amir Emami , P.Eng. is a mechanical engineer and vice president of

engineering at Special Alloy Fabricators (SAF). He has 14 years of experience in valve design, flow analysis and

product development, and has led the engineering team with a dedicated approach to custom designing flow equipment for the last nine years.

Maria Aguirre, P,Eng., edited this article and is a mechanical engineer and business development manager at SAF. She holds a master’s degree in engineering and has 14 years of experience in the valve and automation industry

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SUMMER 2024

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