Following every new capital plant coming online or new expansion beginning production, the hard reality of day to day maintenance becomes critical immediately. Most operations are staffing lean to keep labor costs at a minimum; this requires a repair service to replace parts. Most operations have a couple of good welders on staff to form the nucleus of an operations maintenance crew; however, this limits allowable for many major repairs.
Due to plant maintenance crews short staffed nature, CTI-X7® Ceramic Plant Maintenance is an in-depth service geared to compliment operations on a large or small scale. Our sales and service engineers are on call to gather baseline information on many items that listed throughout CTI’s Catalog of Products. Our engineering department strives to help customers realize all their maintenance needs. With clear-cut field details and after extensive discussion with the customer, CTI’s engineering staff does a preliminary drawing for the quote and defines material design for customer’s review and approval.
This process generates a quick response quote for the desired maintenance product. On receipt of PO, CTI’s dedicated sales and engineering staff confer to detail drawing for customer approval to verify the design. In most cases, a finished product will be delivered to customer’s plant within 4-6 weeks after receipt of final drawing approval. To improve on this delivery schedule, CTI maintains an extensive drawing library to reissue maintenance items as needed. We feel this approach supports your operations and augments a complete integrated service. We have for many years enjoyed working with many of our operational customers to advise and get in place high wear replacement contingencies to support safe and efficient operations.
We are proud to offer Made in Virginia Custom Fabrications and strive to utilize materials made in the USA in every fabrication.
CTI Bottom Ash Systems
CTI-X7® Primary and Secondary Bottom Ash Cyclones, along with the CTI-X7® 6" and 8" pneumatic pipe and fittings with 1/2" ceramic liner, has benchmarked a much improved ash system transport from boiler to silo.
The improved performance has dramatically reduced recurring maintenance man hours as to cyclone repairs, as well as ash pipe and fitting replacement to meet stringent environmental standards.
CTI 24x7 Coal & Mineral Process Distributors
Coal and mineral process requires accurate stage distribution of the process flow. In most cases, coal and mineral slurries are pumped and directed to primary process equipment. Cyclone feeds are one of the most critical in maintaining a balanced, even flow from distribution point to process equipment. Distributors may be as little as a 2-way to as many as a 31-way arrangement.
Material flow wear is very aggressive, and high wear normally requires maintenance in less than a year to traditional steel distributors. The CTI-X7® ceramic lined distributors will see five to ten years life on a 24x7 process schedule.
CTI Bottom Ash Fittings
8" and 10" CTI-X7® Bottom Ash pipe fittings with removable wear backs lined with 1" ceramic tile to combat small particle, high-velocity wear. We see up to five times the life of OEM high chrome parts at present. By eliminating wear pockets that result in partial plugging, our fittings keep flow FPS consistent. Cutting down the potential for gas and dust explosions which can happen when there are slower velocities.
CTI OEM Replacement Cyclones
The heavy media cyclone circuit continues to be the choice as to the coal preparation process. We are now processing nominal 3" by 1/4" coarse flows. The flow impact and wear is aggressive. We can design to tweak wear and separation performance. We supply complete CTI X7® Ceramic HM cyclone arrangements as well as parts.
We will pick up and evaluate your cyclone for full replacement or repair parts as needed. We guarantee accuracy of parts fabricated at 1/16". In 32 years, we have never failed to deliver parts which meet our customer's expectations.
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CTI Process Piping
CTI-X7® Coal and Mineral Ceramic Process piping is a versatile and cost-effective solution to pumping high volume solids on a 24 x 7 process schedule. By detailing a carbon steel, Schedule 40 Pipe Standard with ceramic, we can design for specific wear problems that large particle, dense medium processes create in a predictable and cost effective standard.
CTI Suction & Pump Discharge
CTI-X7® Sump to Pump intake suctions are set up to provide maximum cross section flow to mineral process pumps handling a full range of 3" to 1mm particle size.
The flow to pump intake is typically a schedule 40 pipe with 1/2" tile liner with optional 1" liner in eccentric or concentric reducers.
We recommend blind flange arrangements over mechanical seal options at the sump entry point as being more cost effective and operational at 10+ years.
The CTI-X7® Pump to Pipe Adapter replaces rubber expansion pump to pipe connection. The ability to make 45 degree discharges angles directly off pumps pumping 3" sand-laden slurry has been standard for years with no failures of pump heads or pump adapters.
CTI Segmented Elbows
CTI-X7® remains a key designer and manufacturer for complete ceramic-lined piping systems, including ceramic lined pipe elbows throughout the coal, power and minerals industries. Our systems include designs that are specific to handling large particulate flows through Coal Pump Suctions to complete large diameter Heavy Media Lines to deal with impact and blowout conditions.
We also design and build hydraulic/pneumatic transport for sands, base minerals tailings, or bottom ash. The distinctive fitting designs incorporate flexibility, delivering a 10 to 1 extended life.