The client had installed several v-port ball valves to modulate the flow of diluted froth slurry. Upon 4-5 months in service, the ball valves were severely eroded and the piping required rotation (or replacement). Isolation knife gate valves were also installed downstream to provide tight shut-off, however they too were damaged by the flow.

To visually explain the situation, SAF engineers recreated the piping system (as a 3D model), and simulated the exact process flow conditions via CFD. The results show high-velocity flow being projected to one side of the ball valve, downstream piping and knife gate valve (see Fig 1). This was consistent with the wear patterns observed at site.