Client: Delkor
Location: Global OEM manufacturing & deployment
Project Type: Design Assurance, Failure Mode Analysis & Manufacturing Support
Project Value: AUD $1 million
Project Duration: 2010
Role: Independent Design Peer Review, Performance & Failure‑Mode Authority
Strategic Objective
Delkor designs and manufactures high‑performance thickeners and clarifiers deployed in demanding mining and process‑plant environments. As equipment size increases, so does the consequence of failure—structural, mechanical, operational, and reputational.
Delkor engaged independent expertise to validate, stress‑test, and de‑risk the design and manufacture of its 8m, 12m, and 16m thickeners and clarifiers, ensuring performance, reliability, and manufacturability at scale.
The objective was to deliver defensible design assurance—supporting confident manufacturing, deployment, and long‑term operation under stringent environmental and duty conditions.
The Challenge / Need
Large thickeners and clarifiers operate at the intersection of:
- Significant structural loads
- Continuous mechanical duty
- Process variability
- Harsh operating environments
Key challenges included:
- Ensuring structural and mechanical integrity across multiple size classes
- Identifying latent failure modes before manufacture and deployment
- Balancing design innovation with manufacturing practicality
- Protecting long‑term performance, availability, and maintenance outcomes
- Providing assurance that designs would scale without introducing hidden risk
Once manufactured and installed, remediation options are limited—failure prevention had to occur at the design stage.
Project Scope
The engagement covered independent technical assurance across:
- Design peer reviews for 8m, 12m, and 16m thickeners and clarifiers
- Structural and mechanical performance assessments
- Failure Mode and Effects Analysis (FMEA)
- Manufacturing support and real‑time design clarification
- Alignment of design intent with fabrication and assembly realities
Our Approach
A first‑principles, failure‑led engineering review methodology was applied—focused on decision quality, not paperwork.
Key elements included:
- Independent Design Peer Reviews: Validation of structural, mechanical, and load‑path integrity
- Performance Assessments: Evaluation of operational behaviour against duty cycles, load cases, and process demands
- Failure Mode Analysis: Systematic identification of potential failure points and risk drivers
- Manufacturing Alignment: Direct engagement with fabrication teams to ensure designs were buildable, repeatable, and quality‑controlled
- Design Refinement Support: Practical recommendations balancing performance, durability, and manufacturability
The intent was to eliminate ambiguity before steel was cut.
Risks and Challenges
Key risks requiring deliberate management included:
- Over‑design driving unnecessary cost and complexity
- Under‑design exposing long‑term structural or mechanical failure risk
- Design assumptions misaligned with real manufacturing tolerances
- Scaling effects between 8m, 12m, and 16m units introducing nonlinear risks
These risks were mitigated through independent scrutiny, failure‑mode thinking, and close collaboration with Delkor’s engineering and manufacturing teams.
Solution & Key Deliverables
The engagement delivered:
- Independent design peer‑review reports for all three thickener and clarifier sizes
- Performance assessment findings with optimisation recommendations
- Comprehensive failure‑mode analyses identifying and mitigating potential vulnerabilities
- Manufacturing support ensuring design intent was preserved through fabrication
- Clear technical assurance supporting confident production and deployment
Outcome
The project achieved:
- Validated, defensible designs across all size classes
- Improved structural robustness and operational reliability
- Strong alignment between design engineering and manufacturing execution
- Reduced risk of in‑service failure or performance degradation
- Increased confidence for Delkor in scaling and deploying equipment globally
Delkor gained engineering certainty where it matters most—before manufacture and installation.
Value‑Added Differentiator
- Failure‑Mode First Thinking: Risk identified and eliminated early, not managed later
- Independent Authority: Objective, defensible design assurance
- Manufacturing‑Aware Engineering: Designs validated against real fabrication conditions
- Scale Discipline: Clear understanding of how risk changes with size
- Collaborative Engagement: Engineering assurance delivered without disrupting OEM momentum
For more visit our affiliate Qfactor Performance Consulting
