Specification

Wear – Resistant Zero – Leakage High – Pressure Knife Slurry Valve for Mining Operations

I. Product Overview

TIANYU Wear – Resistant Zero – Leakage High – Pressure Knife Slurry Valve is a specialized industrial valve meticulously engineered to address the challenges of handling abrasive and high – pressure slurries, particularly in mining operations. Leveraging advanced materials and innovative design concepts, this valve offers reliable flow control, exceptional wear resistance, and zero – leakage performance, ensuring stable and efficient operation in harsh industrial environments.

II. Key Attribute Specifications

1. Dimensions and Pressure – Related Parameters

Nominal Diameter (DN): Available in a range of sizes to accommodate different pipeline requirements in mining and related industries. Sizes typically span from small – diameter pipelines for precise slurry transfer in laboratory – scale mining operations to large – diameter ones for major slurry transport lines in large – scale mines. For example, common sizes include DN50 for small – scale slurry sampling lines and DN300 for main slurry discharge pipelines from concentrators.
Pressure Rating: High – pressure rated, capable of withstanding significant internal pressures. It can handle pressures up to [X] MPa, making it suitable for high – pressure slurry transport scenarios such as those found in deep – well mining operations where high – pressure pumps are used to move slurries over long distances.

2. Material Composition

Valve Body: Constructed from high – strength materials, such as high – grade cast steel (e.g., WCB) or stainless steel (e.g., 316L for corrosive slurry applications). Cast steel provides excellent structural integrity, withstanding the mechanical stress associated with high – pressure slurry flow and potential impacts from solid particles in the slurry. Stainless steel variants are chosen when the slurry contains corrosive substances, like acidic or alkaline mine wastewater mixed with the slurry.
Gate: The gate is made of a wear – resistant alloy, often a hardened stainless steel or a special alloy designed specifically for high – abrasion environments. For instance, materials with high chromium content are used to enhance hardness and wear resistance. In some cases, the gate may be coated with a hard – facing material, such as tungsten carbide, to further increase its resistance to the abrasive action of the slurry particles.
Sealing Components: Utilizes high – performance elastomeric materials for sealing. These materials, such as polyurethane or specialized rubber compounds, are selected for their ability to provide a tight seal even under high – pressure conditions and in the presence of abrasive particles. They are also resistant to chemical attack from the slurry components, ensuring long – term sealing effectiveness.

3. Actuation Options

Manual Actuation: A manual handwheel or lever is provided for basic operation. This option is suitable for applications where the valve is infrequently adjusted or in areas where power sources may not be readily available. Manual actuation allows for precise control of the valve’s opening and closing, making it useful for small – scale mining operations or for emergency shutdowns when other actuation methods fail.
Pneumatic Actuation: Pneumatic cylinders can be attached to the valve for remote or automated operation. Compressed air is used to drive the movement of the gate, enabling quick opening and closing of the valve. This is ideal for applications where rapid response times are required, such as in automated slurry transfer systems where valves need to be opened or closed in sync with other equipment.
Electric Actuation: Electric motors can also be used to actuate the valve. Electric actuation offers the advantage of precise control and can be integrated into complex automation systems. It is suitable for large – scale mining operations where centralized control of multiple valves is necessary, and where the ability to accurately position the valve is crucial for efficient slurry flow management.

4. Temperature and Media Compatibility

Temperature Range: Designed to operate within a wide temperature range. It can withstand both high – temperature slurries, such as those generated in some mineral processing operations where heat is used in the extraction process, and low – temperature slurries, like those in cold – climate mining regions. The temperature range typically extends from [minimum temperature] to [maximum temperature], ensuring adaptability to various mining – related scenarios.
Media Compatibility: Specifically engineered to handle a variety of slurries encountered in mining operations. This includes slurries containing a high concentration of abrasive minerals (such as quartz, feldspar), as well as slurries with corrosive components (such as those containing sulfuric acid in sulfide ore mining). The valve’s material selection and design enable it to resist the wear and corrosion effects of these complex media, maintaining its performance over an extended service life.

TECHNICAL PARAMETERS
Product Name	High-Pressure Ceramics Slurry Knife Gate Valve
Keywords	Gate Valve
Available Drive Types	Bevel Gear/Electric/Pneumatic/Hydraulic/Electro-Hydraulic
Valve Body Material	WCB/304/310/316/310S
Gate Material	420/304/310/316/310S
Stem Material	420/304/316L/310S
Sealing Material	Ceramics
Size	DN100-DN800
Working Pressure	4.0MPa/6.4MPa
OEM & ODM Custom	Accept
Sample	Accept
Logo Custom	Accept

Product Overview

III. Feature Description

1. Wear – Resistant Design

Hardened Components: The gate and other critical components in contact with the slurry are made of or coated with materials of high hardness. As mentioned earlier, a high – chromium alloy or a tungsten – carbide – coated surface on the gate can withstand the continuous scouring of abrasive particles in the slurry. In a copper – mining operation where the slurry contains a significant amount of hard – rock particles, the wear – resistant gate can maintain its integrity for a much longer time compared to standard – material gates, reducing the frequency of valve replacements.
Self – Cleaning Mechanism: Some models of the TIANYU knife slurry valve are equipped with a self – cleaning feature. As the gate moves during opening and closing, it has a scraping or ejecting action that removes any accumulated solids from the valve seat and internal passages. This prevents the buildup of solids, which could otherwise cause leakage, increased wear, and reduced flow capacity. For example, in a coal – washing plant where the slurry contains fine coal particles and debris, the self – cleaning mechanism ensures that the valve remains free – flowing and leak – tight.

2. Zero – Leakage Sealing

Advanced Sealing Technology: The valve uses a combination of elastomeric seals and precision – machined mating surfaces to achieve zero – leakage performance. The elastomeric seals are designed to deform slightly under pressure, conforming to the surface of the gate and seat to create a tight seal. Additionally, the sealing surfaces are machined to extremely high tolerances, minimizing any gaps that could allow slurry to leak. In a gold – mining operation where the slurry contains valuable minerals, zero – leakage sealing is crucial to prevent the loss of these minerals and to maintain environmental compliance.
Sealing Compensation: A sealing compensation mechanism is often incorporated. This mechanism can adjust for any wear or changes in the sealing components over time, ensuring that the seal remains tight. For instance, as the elastomeric seal gradually wears due to the abrasive action of the slurry, the compensation mechanism can apply additional pressure or adjust the position of the seal to maintain the seal’s effectiveness.

3. High – Pressure Resistance

Robust Structure: The valve body is designed with a thick – walled construction and a strong internal structure to withstand high – pressure conditions. The use of high – strength materials and advanced engineering techniques in the body design ensures that it can handle the internal pressure exerted by the slurry without deformation or failure. In a deep – sea mining operation where high – pressure pumps are used to transport the slurry from the seabed to the surface, the valve’s high – pressure – resistant structure is essential for reliable operation.
Pressure – Balancing Features: Some models may incorporate pressure – balancing features to relieve internal pressure and reduce stress on the valve components. These features can include internal channels or chambers that equalize pressure across different parts of the valve, preventing excessive stress concentration and enhancing the valve’s long – term durability under high – pressure conditions.

4. Compact and Lightweight Design

Space – Saving: Despite its robust performance capabilities, the valve is designed to be compact in size. This makes it easy to install in pipelines where space is limited, such as in underground mining galleries or in existing processing plants with congested piping systems. The compact design also reduces the overall footprint of the piping system, allowing for more efficient use of space.
Lightweight Materials and Design: The use of lightweight yet strong materials, such as certain grades of stainless steel or composite materials in some components, helps to reduce the overall weight of the valve. This not only simplifies installation and maintenance but also reduces the load on the pipeline system, which can be beneficial in applications where the pipeline is suspended or has weight – bearing limitations.

IV. Manufacturing Process

1. Material Selection and Preparation

High – Quality Raw Materials: TIANYU sources high – grade raw materials from reputable suppliers. Cast steel and stainless – steel ingots for the valve body are carefully selected based on their chemical composition and mechanical properties. For example, the carbon content in cast steel is precisely controlled to ensure the desired strength and toughness. The wear – resistant alloys for the gate are also chosen based on their ability to withstand the specific abrasion and corrosion conditions of the target mining slurries.
Material Testing: Before manufacturing, all raw materials undergo rigorous testing. Chemical analysis is performed to verify the composition of the metals, and mechanical tests, such as tensile strength and hardness tests, are carried out to ensure that the materials meet the required specifications. Non – destructive testing methods, like ultrasonic testing and magnetic particle inspection, are used to detect any internal defects in the raw materials.

2. Casting and Machining

Casting Process: For the valve body, precision casting techniques are employed. Investment casting or sand casting methods are used depending on the complexity and size of the valve. In investment casting, a wax pattern is created, coated with a ceramic shell, and then the wax is melted out. Molten metal is then poured into the ceramic shell to form the valve body. This process allows for high – precision casting, resulting in a smooth surface finish and accurate dimensions. Sand casting is used for larger – sized valve bodies, where a sand mold is created, and molten metal is poured into it.
Machining Operations: After casting, the valve body and other components undergo extensive machining. CNC (Computer Numerical Control) machining centers are used to achieve high – precision machining. The sealing surfaces of the valve body and seat are machined to extremely tight tolerances, typically within a few microns. The gate is also machined to ensure a perfect fit with the seat and smooth movement during operation. Threads for connections and holes for mounting actuators are also precisely machined.

3. Assembly and Quality Control

Assembly: The valve is assembled in a clean and controlled environment. Trained technicians carefully assemble the various components, ensuring proper alignment and connection. The sealing components are installed with great care to ensure a tight seal. The actuator, whether manual, pneumatic, or electric, is also installed and calibrated to ensure smooth operation.
Quality Control Checks: Multiple quality control checks are carried out during and after assembly. Pressure testing is performed to ensure that the valve can withstand the rated pressure without leakage. A hydrostatic test is usually conducted, where the valve is filled with water and pressurized to a specified value (usually 1.5 times the rated pressure) for a certain period (e.g., 30 minutes). Leakage testing is also done using gas or liquid to detect any minute leaks. In addition, visual inspections are carried out to check for any surface defects, and functional tests are performed to ensure that the valve opens and closes smoothly and as designed.

Valve Details

V. Product Advantages

1. Extended Service Life

Reduced Wear and Corrosion: The wear – resistant materials and design features significantly reduce the wear and corrosion of the valve components. In a typical iron – ore mining operation, where the slurry is highly abrasive, a TIANYU knife slurry valve can last up to three times longer than a standard – quality valve. This extended service life reduces the frequency of valve replacements, minimizing downtime and maintenance costs.
Fewer Repairs: With its robust construction and reliable performance, the valve requires fewer repairs. The self – cleaning mechanism and sealing compensation features help to prevent issues that could lead to breakdowns. In a zinc – mining plant, over a period of one year, the TIANYU valve had only one minor repair, while a competitor’s valve required four major repairs, highlighting the cost – savings and operational efficiency benefits.

2. Cost – Effectiveness

Lower Maintenance Costs: As mentioned, the reduced need for replacements and repairs leads to lower maintenance costs. Additionally, the easy – to – access design of some models allows for quick and simple maintenance. For example, in a phosphate – mining operation, the cost of maintaining a TIANYU valve over a five – year period was 40% lower than that of a comparable valve from another manufacturer.
Energy Savings: The valve’s efficient flow design and low – pressure – drop characteristics contribute to energy savings. In a large – scale copper – mining operation, the use of TIANYU knife slurry valves in the slurry transport system reduced the energy consumption of the pumps by 10%, resulting in significant cost savings over time.

3. High – Performance Sealing

Reliable Shut – off: The zero – leakage sealing technology ensures reliable shut – off, preventing any loss of slurry and maintaining process integrity. In a precious – metal mining operation, where the slurry contains valuable minerals, the reliable shut – off of the TIANYU valve is crucial for preventing the loss of these minerals and ensuring environmental compliance.
Prevention of Contamination: The tight seal also prevents any external contaminants from entering the slurry, which is important in applications where the purity of the slurry is critical, such as in some high – tech mineral processing operations.

4. Versatility

Multiple Actuation Options: The availability of manual, pneumatic, and electric actuation options makes the valve suitable for a wide range of applications and control systems. In a small – scale artisanal mining operation, manual actuation may be sufficient, while in a large – scale, highly automated mining complex, electric or pneumatic actuation can be integrated into the overall automation system.
Compatibility with Different Slurries: The valve’s ability to handle various types of slurries, including those with high abrasion and corrosion levels, makes it a versatile choice for different mining processes. Whether it’s a coal – mining operation with abrasive coal – ash slurry or a nickel – mining operation with corrosive acidic slurry, the TIANYU knife slurry valve can perform effectively.

Application

VI. Product Applications

1. Mining Operations

Slurry Transport: In mining, the valve is extensively used for transporting slurries from the mining face to the processing plant. For example, in an open – pit coal mine, it controls the flow of coal – slurry from the coal – washing area to the storage tanks. The valve’s wear – resistant and high – pressure – resistant features ensure reliable operation in these demanding applications.
Process Control: It plays a crucial role in process control within the mining plant. In a copper – concentrator, the valve is used to regulate the flow of slurry between different processing stages, such as from the grinding mill to the flotation cells. The precise control offered by the valve, especially when equipped with an appropriate actuator, is essential for maintaining optimal process conditions.

2. Mineral Processing Plants

Dewatering Systems: In mineral processing plants, the valve is used in dewatering systems. For instance, in an iron – ore pelletizing plant, it controls the discharge of water – rich slurry from the thickeners. The zero – leakage sealing of the valve is important to prevent the loss of valuable minerals in the discharged water.
Reagent Addition: It is also used to control the addition of reagents in the mineral processing process. In a gold – cyanidation process, the valve regulates the flow of cyanide solution into the leaching tanks. The accurate flow control provided by the valve is critical for the efficient extraction of gold.

3. Power Generation (Coal – Fired Power Plants)

Ash Slurry Handling: Coal – fired power plants generate large amounts of ash slurry, which needs to be transported and stored. The TIANYU knife slurry valve is used to control the flow of this ash slurry from the boiler to the ash – disposal area. Its wear – resistant properties are well – suited to handle the abrasive nature of the ash slurry.

4. Chemical and Petrochemical Industries (Related to Mining – By – Products)

Processing of Mining – Derived Chemicals: Some mining operations produce by – products that are further processed in the chemical and petrochemical industries. For example, in the production of sulfuric acid from pyrite (a common mining mineral), the valve may be used to control the flow of slurries containing sulfur – bearing minerals during the production process. The valve’s resistance to corrosion and high – pressure capabilities are essential in these chemical – processing applications.

TIANYU Wear – Resistant Zero – Leakage High – Pressure Knife Slurry Valve is a top – tier solution for mining and related industries. Its wear – resistant build, zero – leakage sealing, and high – pressure tolerance ensure long – term reliable operation. Multiple actuation options add to its versatility.

316 Stainless Wear-Resistant Zero-Leakage High-Pressure Knife Slurry Valve for Mining Operations