HOME CONTACT US ABOUT

  SLURRYTECH ®  WRC  - Wear Repair Compound

 
Achieve maximum equipment wear resistance and reduce costs with Slurrytech Wear Repair Compound (WRC). WRC is an epoxy wear patch system designed to create value and offer safe solutions, WRC has been extensively field tested and is a proven superior wear resistant material. It consists of a trowlable ceramic filled polymer with a technologically advanced formulation that delivers:

• Maximum wear resistance and temperature performance in a wide variety of wet and dry applications
• User-friendly, odour-free, non-hazardous, non-corrosive materials for safe shipping, storing, and handling
• Reduced costs and increased maintenance savings due to reduced erosion and decreased downtime
• Ability to be formulated for specific wear applications and environments
• Rapid curing system within 1 to 2 hours at room temperature; as quick as 15 minutes at elevated temperatures

 

Maximum Protection...                                         

Created, tested and perfected in the lab and field WRC systems were designed to resist wear and abrasion for extended periods of time in both wet and dry applications and in a wide range of varying temperature applications. Our WRC range utilises 2 blends of materials:
 

• WRC-1C, Coarse – A blend of large and smaller sized SiC in a non-sagging Kevlar epoxy blend matrix.
• WRC-1S, Smooth – A blend of smaller SiC particles forming a smooth trowelable compound

To achieve this maximum level of durability, the process begins with a mixture of ultra-high loading levels of silicon carbide (SiC) particles, DuPont Kevlar® fibres and state-of-the-art epoxy systems. This unique non-sagging patching system provides the ultimate wear resistant solution.

 

Wear Solutions...                                 

WRC is designed to maximize equipment lifetime while reducing overall costs. Through advanced technology and flexibility to perform customized applications, WRC can meet the demands of a large variety of specific wear environments. With WRC, equipment erosion and corrosion is reduced, resulting in increased maintenance savings, reduced overall repair costs, and decreased downtime. WRC is designed not only to maximize equipment lifetime and increase maintenance savings, it is formulated with the end-user in mind. In a carefully controlled, cure-staged process, WRC is created as an odour-free, non-hazardous and non-corrosive epoxy system. WRC offers a safe and effective wear resistant solution for today’s aggressive environments.

1. WRC-1C-
2. Nordbak – Fine Grit
3. Belzona
4. Nordbak - Course Grit

 

As can be seen from the above slurry pin test, our SiC filled epoxy has a much better wear resistance.
The pin test is designed to spin the pin in a water and sand slurry at a speed to create a 10 meter a second face velocity.

WRC stands alone in performance for cost value with a wear life ratio up to six times that of competitors products. Easy to use and apply, inert and safe to use WRC sets a new standard in the field of wear part repairs.

The graphs below show the exceptional performance of the WRC product.

 Product Packaging...                           

 

Part No. Description Comments
WRC-4C Wear Repair Compound Coarse (4 lt - 6 kg)  4 lt Localised wear repair 
WRC-4S Wear Repair Compound Smooth  (4 lt - 6 kg)  4 lt Broad application repair 
WRC-1C Wear Repair Compound Coarse (1 lt - 1.5 kg)  1 lt Localised wear repair 
WRC-1S Wear Repair Compound Smooth (1 lt - 1.5 kg)  1 lt Broad application repair 
WRCAPS-0.5 Active Polymer System Primer (0.5 lt)  Use on alloy parts repairs 
SG0020-20M Silicon Carbide Grit 20 Mesh ~ 1.0mm (0.5kg)  Used for super loading NS 

 

 

 

 

 

Pumps, Cyclones, Hoppers, Chutes, Pipes.... Wear Life Solutions...  

WRC can assist in extending the life cycle of your current abrasive duty pumps.  Based on utilising OEM or even others parts in conjunction with WRC repair compounds along with our thorough understanding of slurry wear mechanics Slurrytech have achieve significant parts cost reductions.

By using parts with a longer initial wear life while maintaining existing maintenance cycles allows for them to be damage repaired with WRC or prior to catastrophic failure. Holing through to re-enforcements is typical for elastomer impellers and parts and generally leads to a catastrophic parts failure with chunking out of material.

Actual Scenario...

Location: Mineral Sand operation in Western Australia.
Equipment: 10/8G-AH Warman slurry pump.
Materials: Polyurethane liners and impeller.
Duty: Heavy sand loading to 45% c/w.
Impeller Life: 20 weeks
Maintenance Cycle: 20 weeks

OBJECTIVES

> Aim to remove impeller and throatbush at 20 week cycle prior to catastrophic failure.
> Rebuild worn areas of impeller and matching components using WRC NS reinforced rebuild material.
> Replace into duty with goal to run for same maintenance cycle.
> Repeat cycle as many times as possible for greater cost effectiveness.

OUTCOMES

> WRC impeller repair achieved 20 week maintenance cycle.
> Newly worn locations rebuilt with WRC.
> Cycle will be repeated indefinitely until impeller is deemed unfit for service.

BENEFITS

> Reduced waste and environmental impact through equipment recycling.
> Reduced cost as impeller will be used through multiple cycles.
> Results and benefits can be applied across plant for additional savings.

Cost Implications...

Historically it was not cost effective to consider parts rebuild with repair compounds as no available product was able to match and / or exceed the parent material wear life. Our WRC range of products have answered this problem with their SiC and Aramid fibre infused epoxy based repair compounds.

Now you can expect to achieve a similar or better result to parent material by using WRC. With Patented compositions our products mimic microstructures of hard wearing carbides in a retaining matrix. With WRC the matrix consists of epoxy that is Aramid fibre reinforced with a matrix of SiC particles specific to the duty and particle size distribution.

Cut, gouge and tear mechanics of wear are retarded significantly. As abrasive solids impinge on the surface of our repair materials they are retarded in their cutting through the high concentration of SiC particles and Aramid fibres which knit the material together.

Used in high wear zones of liners, pipes, screens, mills etc. WRC can significantly reduce the life cost of your abrasive duty machinery. The following Cost Implication Example is based on approximate costs for a 10/8 size slurry pumps main failure components.
 

PARTS REPAIR v's REPLACEMENT

Application Techniques.

WRC-1C can be modified in application to suit the specifics of component repair and duty conditions.

This is achieved through "Super loading" of the compound with additional SiC grit to achieve a higher wear material ratio.

The epoxy phase with it's Kevlar reinforcing can withstand higher loading in areas that are less prone to mechanical stress and forces, typical areas include:

Pump Parts - Side walls, volutes, throatbushes and frame plate liner inserts.

Impellers / Mixer Blades / Propellers - Eye and rear shroud can be super loaded. O.D's can have higher loadings depending on tip speeds, below 28 m/s is a nominal recommendation, this equates to material limitations for elastomer parts before molecular breakdown effects the bond integrity.

Cyclones / chutes / launders / tanks / pipes - All parts can be super loaded for low angle solids impingement. High angle impingement should be incrementally trialed to achieve the highest loading possible without suffering from fracturing and breakout. The less epoxy Kevlar binder the lower the fracture toughness and resistance to impact damage from larger solids.

WRC-1S can also be super loaded specific to application requirements. SC contains high concentrations of smaller SiC particles and is predominantly used for covering larger surface areas on softer wearing applications.

Typical examples are:

Water pump parts on contaminated duties to extend parts life.

Cyclone parts rebuild, followed by application of NS finish coat for known wear zones.

Slurry pumps cast iron Cover and Frame plates, coating of inside of parts to resist wear due to liner blow out.

CURING, curing is achieved through exothermic reaction (heat generating chemical reaction) of the epoxy phase, this can be enhanced and accelerated through the use of a heat gun on a low temperature setting for small repairs or an industrial heater below 55 deg C for larger areas. Curing time is a function of ambient temperature and component temperature, accelerated heating can reduce curing time to 20 mins for urgent repair jobs. All compounds can be used on Alloy, Rubber and Polyurethane materials to effect long lasting repairs. Poly and Alloy benefit greatly from the use of the APS primer system which increases the bond integrity. For alloy parts where possible it is recommended to preheat the local repair area so it does not act as a heat sink.
 

Field Results, Proven in Service...      

2007 - 2008 Coal Washing Plant

Problem: A schedule 30 material discharge elbow made of carbon steel was wearing out in 30 - 40 days.

Solution: The carbon steel elbow was coated inside with a 3⁄4" layer of WRC NS and smoothed with water to give an even, smooth surface.

Result: After 4 months of operation, the elbow did not show signs of wear. Client saved approximately $10,000 in downtime costs.

2007 - 2008 Iron Ore Processing Plant

Problem: Magnetic separators, guides, pipes, and steel conveyors need regular epoxy patching due to wet wear conditions. The main issues are cure time and safety with performance over competitive epoxies being secondary considerations.

Solution: Installed WRC NS on magnetic separators, guide trays, and transfer pipes.

Result: Workers were pleased by the lack of odour and the 3 - 4 hour cure times. In addition, these mines will use industrial hot air guns and torches for curing. WRC can be cured with an 850 0 F hot air gun in less than 10 minutes.

2008 - 2009 Silica Sands Plants

Problem: Attrition mill paddles were wearing out within 30 days. The prior protective layer had been Tungsten carbide.

Solution: In an emergency, the plant shut down due to paddle wear. WRC NS used as a “temporary” quick fix repair until the next scheduled shut down.

Result: WRC lasted for 90 days with three times the performance of Tungsten carbide realized at a fraction of the cost.

2007 - Silica Sands Plants

Problem: Attrition and wear of rubber slurry pump impeller in 15 weeks.

Solution: Modified application of WRC NS with "Super Loading" of SiC particles.

Result: WRC lasted for 15 weeks with ~10 to 15% wear compared to parent material. Impeller placed back into service for another 15 week run with a target to repair and reuse for 3 to 4 maintenance cycles. Additional benefits are reduced environmental impact through reuse of parent part.

2007 - 2009 - Mineral Sands Plants

Problem: Attrition and wear of polyurethane slurry pump impeller in 20 weeks.

Solution: Modified application of WRC NS with "Super Loading" of SiC particles.

Result: WRC lasted for 20 week cycle with ~ 50% wear compared to parent material. Impeller repaired with WRC NS placed back into service for another 20 week run with a target to repair and reuse for 3 to 4 maintenance cycles. Additional benefits are reduced environmental impact through reuse of parent part. Successful application can be applied across plant for additional benefits.

    

 

SLURRYTECH ® - PARTS THAT LAST

Copyright 2009, Slurry Technology Group Pty Ltd
SLURRYTECH
  ®
is a registered trademark of Slurry Technology Group Pty Ltd
CERAMAX ® is a registered trademark of Slurry Technology Group Pty Ltd

LEGAL DISCLAIMER

All registered names, trademarks, copyrights and part numbers remain the property or their respective owners. All use of OEM names, part, model and item numbers are for reference and identification purposes only.

SLURRYTECH® is a registered Trade Mark of Slurry Technology Group Pty Ltd. WARMAN® is a registered Trade Mark of Weir Minerals. AES® is a registered trademark of AES Seals

SLURRYTECH® products are not sponsored, endorsed or approved by Weir Minerals. Slurrytech are not an endorsed reseller or representative of Weir Minerals or their respective products.

SLURRYTECH® products do not infringe on Trade Marks Act 1995 or Copyright Act 1968, and to the best of our knowledge and through investigation we are not in contravention of any current patents.