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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 Industry: Silicon powder venting.
- ⚗️ Coal Chemical Industry: 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 Machinery: Jacketed solution valves.
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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)
Q What makes the FCCV5 ceramic ball valve suitable for high-temperature and high-pressure applications?
The FCCV5 features all hard-sealing surfaces with no graphite or PTFE, a dovetail groove housing seal with a wide spiral wound gasket, and an extra-large ceramic ball that provides double the strength of conventional designs. These characteristics ensure reliable performance under extreme temperatures and pressures without leakage.
Q Which ceramic material is recommended for the most demanding corrosive environments?
ZrO₂ (Y-TZP) and 99 Al₂O₃ are generally recommended for highly corrosive environments due to their excellent corrosion prevention ratings (Grade A) across most acids and alkalis. SiC also demonstrates outstanding corrosion resistance, particularly against hydrofluoric acid (HF), where ZrO₂ may be less suitable.
Q How does the "Live Load" packing system extend the service life of the valve?
The "Live Load" packing system maintains a constant sealing pressure by automatically compensating for packing wear over time. This eliminates the need for frequent manual adjustments, reduces maintenance downtime, and significantly extends the operational life of the valve's sealing components.
Q What industries and applications is the FCCV5 ceramic ball valve 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 valves, and any environment involving extreme erosion, corrosion, and thermal shock.
Q What size range is available for the FCCV5 ceramic ball valve, and how does the flow coefficient vary?
The FCCV5 is available in sizes from DN15 to DN200. The flow coefficient (Cv) varies depending on the ball core type — O-type, V60°, V45°, or V30° — allowing precise flow control for different process requirements. For example, a DN200 O-type ball core has a Cv of 1822, while a V30° core provides 514 for fine regulation.
Q How does the FCCV5 compare to conventional metal ball valves in terms of wear resistance?
Ceramic materials used in the FCCV5, such as Y-TZP ZrO₂ and Si₃N₄, offer hardness values of 87–92 HRA and compressive strengths up to 2800 MPa, far exceeding conventional 45# steel (36 HRC, 2000 MPa compressive strength). This results in dramatically superior wear resistance, especially in abrasive slurry and erosive media applications, leading to longer service intervals and lower total cost of ownership.