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Chesterton® ARC Composites Used for Path Repair of Coal Cyclone


Case study AU0011 – Chesterton ARC products – Industrial Coatings

Chesterton - Global Solutions, Local Service



A customer required maintenance on their cyclones after the engineered ceramic tiles fractures and disbonded with the high impact of reject coal. Replacement of these units can be expensive and costly when it comes to downtime. The customer wanted to extend uptime and lower maintenance costs, and so Chesterton recommended two of our Chesterton® ARC composites to solve the problem. With these products applied, production was able to begin in 24 hours after downtime, rather than the several weeks it would take for replacements.

Products featured in the case study:

Chesterton ARC BX1.

Chesterton ARC MX1.



Replacement tiles or cyclones are not readily available, meaning extensive downtime and production losses occur.

Root Cause

Engineered ceramic tiles fracture and disbond with the high impact from the reject coal.


Extend uptime and lower maintenance costs.

Damaged cyclone before Chesterton intervention.


Damaged and holed out cyclone bodies can be readily repaired by abrasive blasting and trowel applying Chesterton® ARC composites.

Chesterton® ARC BX1 and ARC MX1 are a fast and effective way to get the plant on line and can be force cured for even faster turnaround.

Chesterton® ARC BX1 and ARC MX1 industrial wear resistant coating are designed to:

  • Protect areas exposed to sliding abrasion
  • Resurface damaged metal in lieu of more traditional weld overlays
  • Replace ceramic tiles and rubber linings, which can disbond easily
  • Restore worn equipment to near original condition
  • Easily apply by trowel

Coating application.


In this case, the coal preparation plant was back on line in 24 hours compared to several weeks for new replacements.

Repaired cyclones are now part of inventory, just in case a failure occurs; allowing huge downtime savings.

Recycling of old cyclones and repairing with our Chesterton® ARC composites, saves valuable time and money. Downtime savings, approximately $40,000 per hour.

Repaired cyclone.

About Us

Chesterton global solutions, local service

Chesterton® is a world leader in helping process industry companies and manufacturers improve the reliability and efficiency of their rotating, stationary, and fluid power equipment platforms. We are known across a wide range of industries for our award-winning pump and valve sealing solutions, applications expertise, equipment maintenance and wear-prevention products, and knowledgeable hands-on local service​.

Mentioned in this case study:


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Case Study AU0011 – Issued 08/21

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