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Cyclone separator life improvement with Chesterton® ARC Industrial Coating


Cyclone separators are used to remove finer dust particles from heavier ALOH4 during the comminution process.  These solids tend to wear the inside of the separators due to the cyclonic nature of the material flow inside the separator.

Generally, cyclones in this plant last 27,000 tonnes processed (approximately 6 months) before they become so worn that holes appear in the walls allowing valuable process materials to escape.

Several repair methods have been tried including welding steel pads over affected areas and the use of rubber linings however, this leads to inefficient material flow and therefore loss of product to waste.

A complete replacement separator unit was the only option.

Typical alumina cyclone separator

Products featured in this case study:

Chesterton ARC BX1


Applying Chesterton ARC BX1 6 mm coating along the inside of the replacement separator wall which will ensure a more laminar flow of the solid particles around the separator itself, smooth out any areas where solids can penetrate and ensure the substrate material is protected against the abrasive nature of the alumina particles.

This will also ensure that the separator walls will last beyond the usual six-month lifespan, with an expectation of at least two years usage.  It will also mitigate any process fluid leaks and allow for field repairs rather than another costly replacement.

Cyclone separator wall coated with ARC BX1 after 9 months service – very little wear

Chesterton ARC BX1 – 100% solids, modified epoxy formulation, reinforced with a proprietary blend of ceramic beads and powders for severely abrasive, sliding wear environments.

ARC BX1 industrial wear resistant coati​ng is 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
  • Easily apply by trowel​​​​​​​​​​​​​


All amounts shown are in USD


Complete separator replacement costs

New Separator (CHT100 steel) = $200,000
Trades costs to disassemble the old separator = $100,000
Trades costs to install the new separator = $200,000
Plant downtime to execute each replacement = 30 days

Total cost of replacement = $500,000 and 30 Days


Chesterton ARC coating solution repair costs

BX1 to cover the entire separator walls: $47,750
Trades costs to apply BX1 = $50,615
Plant downtime to execute each repair = 10 days

Total cost of shutdown = $98,365 and 10 Days

ROI = 2.4 months ($401,635 saving + 20 loss of production days at $68K per day = $1,360K)

About Us

Chesterton® ARC coatings are specifically formulated and engineered to be used in a wide range of harsh environments and conditions.

With outstanding adhesion, superior mechanical strength, excellent permeation, chemical and wear resistance, 100% solids and solvent-free, the available range of Chesterton ARC coating will help you protect your investment.

® Registered trademark owned by A.W. Chesterton Company

Issued 06/2022

Technical data reflects results of laboratory tests and is intended to indicate general characteristics only. A.W. Chesterton Company disclaims all warranties expressed or implied, including warranties of merchantability and fitness for a particular purpose. Liability, if any, is limited to product replacement only. Any images contained herein are for general illustrative or aesthetic purposes only and are not intended to convey any instructional, safety, handling, or usage information or advice respecting any product or equipment. Please refer to relevant Safety Data Sheets, Product Data Sheets, and/or Product Labels for safe use, storage, handling, and disposal of products, or consult with your local Chesterton sales representative.

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