Case study: ceramic valves in a 1.2 million ton/year fine chemical demonstration project

A prominent chemical company in Inner Mongolia undertook a 1.2 million ton/year fine chemical demonstration project with a total investment of ¥19.2 billion. Located in the Southern Project Area of the Duguitala Industrial Park in Hanggin Banner, Ordos City, this project saw its gasifiers achieve a successful first trial in June 2017 and complete production by the end of August. The gasification system includes nine gasifiers: six aerospace pulverized coal gasifiers and three multi-material slurry coal-water slurry gasifiers.

Gasification System Overview
Coal gasification is a cornerstone of Coal Chemical Processing, relying heavily on gasification equipment, commonly known as gasifiers. The selection and operation of gasifiers are critical indicators of the stability and development potential of coal chemical industries. Among the decisive factors, the choice and application of key instruments play a vital role. Ceramic valves, with their distinct advantages, have proven instrumental in ensuring stable operations under harsh conditions.

Application of Ceramic Valves in Gasification Units
Position: 23602-PV-x128B – Pulverized Coal Feeding Tank Pressure Control Valve
First installed in October 2017, this valve controls a medium of pulverized coal. The original setup used control valves from Fisher, with an average lifespan of three months. Upon replacing them with ceramic Ball Valves, the lifespan significantly increased. Until the process change, these ceramic valves required no maintenance, earning high recognition from the client and paving the way for future applications.

Position: 23701-FV-x008 & 23200-FV-00808A – Black Water Flow Control Valves
Handling black water with high solid content due to coal quality, the initial setup used eccentric rotary valves from Masonilan. Severe erosion often led to valve plates being almost completely destroyed, lasting only 6-8 months.
● In August 2018, KOWOV ceramic valves were deployed in the pulverized coal gasifier.
● By October 2019, they were used in the coal-water slurry gasifier. Initially, ceramic C valves were installed, achieving a maximum lifespan of 12 months. Subsequent inspections revealed significant erosion marks.
● Technical innovations led to a redesigned ceramic sliding valve solution, introduced in late 2020. This solution demonstrated exceptional performance, extending the average lifespan to over 24 months.

Position No.: 23701-FV-x008 Black water flow regulating valve at the outlet of pulverized coal quenching water pump

Position No.:23200FV-00808A  Water-coal slurry quenching water flow regulating valve
Position: 23300-LV-00703A/803B/903C – Low-Pressure Flash Tank Level Control Valves
Handling black water with fine ash particles and significant erosion, the original ceramic ball valves were replaced with ceramic sliding valves in January 2022 due to their superior anti-erosion capabilities.

Position No.:23300LV-00703A/803B/903C Low pressure flash level regulating valve
Position: 23200-LV-02112A – Coal-Water Slurry Scrubber Tower Level Control Valve
Installed in October 2019, the ceramic ball valves for this high-pressure gray water application met the expected lifespan. Subsequent replacements also opted for ceramic sliding valves.

Position No.: 23200LV-02112A Water-coal slurry washing tower liquid level regulating valve

The Role of Ceramic Valves in Coal Chemical Processing
Ceramic valves are central to gasification systems, a critical stage in coal chemical processing. The processed media, predominantly black water and gray water, are highly abrasive and corrosive, often operating under high-pressure conditions. These extreme environments rapidly degrade traditional metal valves, jeopardizing operational stability and efficiency.
Ceramic valves, made from advanced structural ceramics, address these challenges with unmatched durability. Their outstanding physical and chemical properties make them the ideal choice for harsh media in coal gasification systems.
At Kingway, we recognize the significance of ceramic valves in the coal chemical industry. By continuously refining valve designs and manufacturing processes, we ensure precise compatibility with coal chemical systems. Our high-performance solutions help clients achieve efficient, reliable, and economical fluid control, contributing to safer, more stable, and environmentally sustainable coal chemical operations.