×Technical panel · September 3
Use of Reliability Tools at the HP Oxide Plant
Wanderson Cipriano de Alcantara
The CBMM HP Oxide plant faced the challenge of increasing production from 6,300 tons in 2023 to 8,000 tons in 2024. To overcome unplanned shutdowns, Maintenance Engineering implemented reliability concepts and developed a Fault Tree Analysis (FTA) to identify critical causes and key assets. It was found that the centrifuge generated high unplanned corrective-maintenance costs of R$550,000 and long shutdowns — 98 hours in the Crystallization system and 32 hours in Calcination. Centrifuge reliability was in the early-failure phase, with only 13% reliability at 30 days. Failure modes such as overcurrent trips and gearbox wear were identified, and corrective actions were implemented. In 2024, new data showed significant progress: the centrifuge reached the useful-life phase, increasing reliability to 25% and MTBF from 18 to 37 days. Corrective-maintenance costs fell to R$159,000, producing savings of R$392,000. Crystallization-system downtime decreased from 98 to 21.8 hours and Calcination downtime from 32 to 2.94 hours, generating an additional 30 tons of HP Oxide. Despite these improvements, reliability still requires further progress.