Overcoming challenging industrial conditions: a case study on ceramic valves in alcohol production
Pioneers of CeramiC Valve Technology
### 1. Background
At one of COFCO Group’s alcohol production units, cassava is used as a raw material. Due to harsh working conditions, valves and pipelines needed frequent replacement, including those coated with Stellite or tungsten carbide, and even Ceramic Valves from other brands. The regulating valve used in the feed system of the filter press experienced severe wear and had an extremely short lifespan.
Working Conditions:
- Medium: Liquefied cassava mash (with sand)
- Temperature: <85°C
- Pressure: 0.72 MPa (inlet), 0.70 MPa (outlet)
- Flow rate: Max 51 m³/h, Normal 30 m³/h, Min 3 m³/h
- Valve size: DN80
---
### 2. Key Issues Identified On-Site
1. Severe erosion: Sand particles in the medium caused extensive wear on valves and pipelines.
2. Frequent valve failures: The valve ball often seized or fractured, rendering the valve unusable.
3. Smooth operation hindered: Blockages led to malfunction, deformation, or even breakage of the cylinder shaft.
4. Leakage issues: Erosion wore down the ball and valve seat, leading to external leaks.
Images:
- Ball component worn down in 7 days
Severe deformation after 15 days
- Heavy erosion in competing Ceramic Valves with a lifespan of only 15 days
Frequent replacements and high maintenance costs made it challenging to maintain stable, long-term operations.
---
### 3. Our Solution
After evaluating the conditions, Yantai Kingway Science & Technology Co., Ltd. recommended our FCCV1 Ceramic Valves:
1. High performance: Designed to withstand temperatures up to 180°C and a pressure differential of 2 MPa.
2. Enhanced durability: All components in contact with the medium are made of high-strength ceramic, resistant to wear and erosion.
3. Superior sealing: Large sealing surfaces and precision-lapped primary seals ensure tight closure.
4. Bidirectional Sealing: Symmetrical design allows for dual-direction flow, effectively doubling the valve’s lifespan.
5. Independent ceramic flange: Protects the metal flange from erosion and corrosion.
Following discussions, the customer chose to conduct a 3-month trial with a 6-month warranty. Our valve was selected through an open bidding process.
### 4. Performance Results
In July 2022, our KOWOV ceramiC Valve was installed on Filter Press #9 and successfully entered service. During operation, the regulating valve performed stably, meeting all process control requirements.
Inspections were conducted on:
- August 17: No signs of wear after the first shutdown.
- September 21 and December 5: After five months of use, the valve was still in perfect condition.
Given the outstanding results, the valve is estimated to last one year in single-direction use and up to two years with bidirectional use.
As of July 2024, the valve remains in continuous operation, and the customer has expressed high satisfaction with its performance.
---
### 5. Comparison with Other Solutions
### 6. Follow-up
Encouraged by the successful trial, the customer decided to switch several valves to ceramic models. However, during procurement, a low-cost competitor’s ceramiC Valve was selected. Unfortunately, within just two weeks, the valve ball fractured, and severe seat erosion forced the system to shut down again.
Faced with this failure, Yantai Kingway responded swiftly, delivering our ceramic valves within the customer’s tight timeline. Once installed, the system was back online, and the operational issues were resolved effectively.
Images:
- Competing valve with cracked ceramic ball and eroded seat
- KOWOV valve in action, performing without issues
### 7. Customer Feedback and Future Plans
The customer praised the KOWOV ceramic valve for exceeding their expectations in challenging conditions. Its durability and reliability during the trial period demonstrated the strength of its design and the quality of the product.
The valve’s superior performance in follow-up inspections delivered substantial economic and operational benefits. Building on this success, the customer now plans to use KOWOV ceramic valves in more projects, showing confidence in both our product quality and service capabilities.
---
This case highlights how Yantai Kingway’s innovative ceramic valve solutions can thrive under harsh conditions, providing customers with long-lasting performance, reduced downtime, and significant cost savings. We look forward to expanding our collaborations and bringing the benefits of ceramic technology to even more industries.