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High Temperature & High Pressure Ceramic Ball Valve FCCV5 - China Suppliers & Factory for Extreme Environments
Structural Characteristics and Advantages
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Extra-large ceramic ball provides double the strength of conventional designs, enhancing reliability under high stress.
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Scraper-type valve seat with broad sealing surface ensures consistent, long-lasting tightness even with abrasive slurries.
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All hard-sealing surfaces with no graphite or PTFE, guaranteeing stability in high-temperature and corrosive media.
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Dovetail groove housing seal with wide spiral wound gasket achieves zero leakage even under pipeline stress or cyclic thermal shock.
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"Live load" packing system maintains constant sealing pressure, automatically compensating for wear and significantly extending packing life.
Application Fields
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Widely used in slag lock hoppers, coal lock hoppers, deslagging systems, pressure relief systems, steelmaking, coal chemical processes, and other industries where extreme erosion, corrosion, and thermal shock occur.
Main Technical Parameters
| Item |
Y-ZrO Y-TZP |
Mg-ZrO₂ M-PSZ |
90 Al₂O₃ | 95 Al₂O₃ | 99 Al₂O₃ | Si₃N₄ | SiC | Common ceramics | Carbide alloy | 45# Steel |
Density g/cm³ |
6.0~6.05 | 5.72~5.74 | 3.45~3.55 | 3.6~3.75 | 3.9~3.95 | 3.2~3.33 | 3.15~3.25 | 3.0~3.5 | 14~18 | 7.8 |
Hardness HRA/C |
87 | 85 | 90 | 90 | 92 | 92 | 94 | 50~60 | 70 | 36 |
Flexural Strength MPa |
1150 | 900 | 350 | 370 | 450 | 1200 | 470 | 20~50 | 2000 | 804 |
Fracture Toughness (KIC) MPa√m |
10~12 | 13~15 | 3.4 | 3.6 | 4.5 | 7 | 4 | -- | 20 | 101 |
Compressive Strength MPa |
2000 | 1800 | 1700 | 2000 | 2200 | 2800 | -- | -- | 4000 | 2000 |
Thermal Shock Resistance °C |
87 | 110 | -- | -- | 50 | 200 | 75 | -- | 500 | 500 |
Thermal Expansion Coefficient ×10⁻⁶/°C |
9.6 | 10 | 7.6 | 7.8 | 8.3 | 3.4 | 4 | -- | 7 | 12 |
Modulus of Elasticity GPa |
200 | 200 | 310 | 330 | 350 | 300 | 400 | -- | 600 | -- |
Crushing Load KN (Φ6mm) |
15 | 10 | 3.5 | 3.6 | 4 | 18 | 3.5 | -- | -- | -- |
Using Temperature °C |
<160 | <1000 | <1200 | <1250 | <1500 | <1500 | <1500 | -- | -- | <560 |
Water Absorption |
0 | 0 | 0.02% | 0.01% | 0.00% | 0 | 0.50% | 5~10% | -- | -- |
Corrosion Prevention |
Good | Good | Good | Good | Good | Good | Good | Flooey | Good | Flooey |
*Data sources: test results or issued original documents.
Anti-Corrosive Performance Reference Table
| Media | Temperature | ZrO₂ | 99.9% Al₂O₃ | SiC | Si₃N₄ | Graphite | PTFE | Fluororubber | SS304 | SS316 | HC |
| 20% HCL | 60°C | A | A | A | B | A | A | A | C | C | B |
| 20% HCL | 95°C | A | A | A | C | A | A | A | -- | -- | C |
| 90% H₂SO₄ | 60°C | A | A | A | A | A | A | A | C | C | B |
| 90% H₂SO₄ | 95°C | A | A | A | B | A | A | A | C | C | C |
| 60% H₃PO₄ | 60°C | A | A | A | C | A | A | A | C | C | A |
| 60% H₃PO₄ | 95°C | A | A | A | C | A | A | A | C | C | A |
| 10% HF | 60°C | C | B | A | A | A | A | A | C | C | B |
| 46% HF | 95°C | C | C | A | C | A | A | A | -- | -- | C |
| 60% HNO₃ | 60°C | A | A | A | C | B | A | A | A | A | C |
| 60% HNO₃ | 95°C | A | B | A | C | B | A | A | B | B | C |
| 30% NaOH | 60°C | A | B | A | B | A | A | A | A | A | A |
| 30% NaOH | 95°C | B | B | A | C | A | A | A | A | B | A |
A ≤ 0.1 mmg/cm²/day: Can be ignored or has no corrosion, recommended for use.
B = 0.1~0.3 mmg/cm²/day: Slight or very minor corrosion, use with caution.
C ≥ 0.3 mmg/cm²/day: Significant corrosion, not recommended for use.
-- Intense corrosion, to the extent that measurement is not possible.
Flow Characteristic Sheet of Ceramic Ball Valve
| Core Specifications | O-type ball core | V60° ball core | V45° ball core | V30° ball core |
| DN15 | 10 | 7 | 4 | 3 |
| DN20 | 18.2 | 12 | 8 | 5 |
| DN25 | 29 | 18 | 12 | 8 |
| DN32 | 47 | 30 | 20 | 13 |
| DN40 | 73 | 46 | 31 | 21 |
| DN50 | 114 | 72 | 48 | 32 |
| DN65 | 181 | 115 | 76 | 51 |
| DN80 | 292 | 185 | 123 | 82 |
| DN100 | 456 | 289 | 192 | 128 |
| DN125 | 712 | 452 | 300 | 201 |
| DN150 | 1025 | 650 | 432 | 289 |
| DN200 | 1822 | 1156 | 769 | 514 |
Typical Applications
Polysilicon Silicon powder venting.
Coal Chemical Coal powder pressure relief valves and regulating valves; slag lock hopper pressure relief and punch valves; quench water flow regulation; high differential pressure black ash water flow control.
Textile Jacketed solution valves.
The FCCV5 represents a technologically advanced and globally unique ceramic ball valve solution, offering unmatched performance, safety, and long-term cost savings in the harshest industrial environments.
❓ Frequently Asked Questions (FAQ)
What makes the FCCV5 ceramic ball valve suitable for high-temperature and high-pressure applications?
The FCCV5 features an extra-large ceramic ball with double the strength of conventional designs, all hard-sealing surfaces without graphite or PTFE, and a dovetail groove housing seal with a wide spiral wound gasket. These features collectively ensure zero leakage and stable performance under extreme temperatures and pressures.
Which ceramic material offers the best performance for abrasive and corrosive media?
For most abrasive and corrosive applications, ZrO₂ (Y-TZP) and Si₃N₄ ceramics offer excellent combinations of hardness, flexural strength, and corrosion resistance. SiC provides the highest hardness (HRA 94) and outstanding corrosion resistance across a wide range of acids and alkalis, making it ideal for highly aggressive media.
How does the "Live Load" packing system extend valve service life?
The "Live Load" packing system continuously maintains constant sealing pressure through spring-loaded components. It automatically compensates for packing wear over time, eliminating the need for frequent manual adjustment and significantly extending the overall service life of the valve packing.
What industries and processes are the FCCV5 ceramic ball valves designed for?
The FCCV5 is designed for use in slag lock hoppers, coal lock hoppers, deslagging systems, pressure relief systems, steelmaking, coal chemical processes, polysilicon silicon powder venting, textile machinery jacketed solution systems, and any environment subject to extreme erosion, corrosion, and thermal shock.
What size range is available for the FCCV5 ceramic ball valve, and what are the flow characteristics?
The FCCV5 is available from DN15 to DN200. It supports multiple ball core configurations including O-type, V60°, V45°, and V30°, offering a wide range of flow coefficients (Cv) to suit precise flow control requirements across different pipeline sizes and process conditions.
How does the corrosion resistance of FCCV5 ceramic materials compare to stainless steel?
Ceramic materials such as ZrO₂, Al₂O₃, and SiC consistently achieve an "A" rating (≤ 0.1 mmg/cm²/day) in most acid and alkali media tests, including HCl, H₂SO₄, H₃PO₄, HNO₃, and NaOH. In contrast, stainless steels SS304 and SS316 frequently receive "C" ratings in the same media, indicating significant corrosion. Ceramics offer far superior chemical resistance for demanding industrial applications.