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DN100 PN16 Pneumatic Ceramic Discharge Double Gate Valve
  • DN100 PN16 Pneumatic Ceramic Discharge Double Gate Valve
  • DN100 PN16 Pneumatic Ceramic Discharge Double Gate Valve
  • DN100 PN16 Pneumatic Ceramic Discharge Double Gate Valve
  • DN100 PN16 Pneumatic Ceramic Discharge Double Gate Valve
  • DN100 PN16 Pneumatic Ceramic Discharge Double Gate Valve

DN100 PN16 Pneumatic Ceramic Discharge Double Gate Valve

Product Attribute: Size:Dn50-Dn400
Design Pressure:Pn10, Pn16
Specification:CE, SGS, GMP
Working Pressure:0.6-1.6MPaType:Straight-through
Material:Carbon Steel
Connection Form:Flange
Pressure:Ordinary Temperature
Actuator:Pneumatic
Seal Surface:Parallel Gate Valve
Thread Position of Valve Rod:Inside Gate Valve
Usage:Regulation, Emptying, Drain, Temperature Control, Flow Control
Application:Industrial Usage, Water Industrial Usage
Origin:Zhejiang
Medium:Dry Ash in Power Plant, Slurry, Cement Ash, Powder
INFO@TYFLUIDGROUP.COM

 

Specification

DN100 PN16 Pneumatic Ceramic Discharge Double Gate Valve

I. Product Overview

TIANYU DN100 PN16 Pneumatic Ceramic Discharge Double Gate Valve is a high – performance industrial valve engineered for harsh – condition applications involving abrasive, high – viscosity, or corrosive media. Leveraging advanced ceramic sealing technology and pneumatic actuation, it delivers reliable flow control, tight sealing, and exceptional wear resistance. Designed to meet the demands of industries like power generation, mining, and chemical processing, this valve ensures stable operation in scenarios such as ash handling, slurry transport, and corrosive fluid discharge, minimizing downtime and maintenance costs.

II. Key Attribute Specifications

1. Basic Dimensions and Pressure Rating

  • Nominal Diameter (DN): DN100, catering to medium – sized pipeline systems. This size balances flow capacity and installation space, suitable for typical industrial pipelines transporting abrasive media like ash slurries or mineral concentrates.
  • Pressure Rating (PN): PN16 (1.6MPa), aligning with low – to – medium pressure industrial pipelines. It can safely handle media pressure in applications such as power plant ash discharge lines (usually 0.6 – 1.2MPa) and mining slurry pipelines, ensuring structural integrity under normal operating conditions.

2. Material Composition

  • Valve Body: Crafted from high – quality cast steel (WCB as standard; optional stainless steel like 304/316 for enhanced corrosion resistance). Cast steel provides robust structural strength, withstanding pipeline pressure and external mechanical impacts. Stainless steel variants are ideal for corrosive environments, such as chemical plants dealing with acidic or alkaline media.
  • Gate and Sealing Components: Utilizes advanced structural ceramics (alumina Al₂O₃ or zirconia ZrO₂ as the main material). Ceramics boast extreme hardness (≥HRC85), far exceeding metal materials in wear resistance. In abrasive media like fly ash (with particles of 50 – 200μm in size) or mineral slurries, ceramic gates and seats maintain surface integrity, resisting particle erosion and prolonging service life.
  • Stem: Made of 2Cr13 alloy steel, featuring excellent corrosion resistance and torque resistance. The stem connects the pneumatic actuator and the gate, transmitting actuation force. Its alloy composition prevents rust and deformation under long – term operation, ensuring smooth gate movement.
  • Packing: Flexible graphite packing is employed. It offers high – temperature resistance (up to 450℃ in short – term, stable at 350℃ for long – term), good sealing performance, and self – lubricating properties. This prevents media leakage along the stem, even under temperature fluctuations and pressure changes, maintaining a clean and safe working environment.

3. Actuation and Control

  • Pneumatic Actuator: Adopts a double – acting (default; single – acting optional for fail – safe requirements) aluminum alloy cylinder. Aluminum alloy combines light weight and corrosion resistance, reducing the valve’s overall weight and easing pipeline load. The double – acting mode enables fast opening and closing (full stroke within 3 – 5 seconds), crucial for emergency shutdowns in ash handling systems to prevent pipeline blockages.
  • Control Compatibility: Equipped with limit switches and solenoid valves, seamlessly integrating with DCS (Distributed Control System) and PLC (Programmable Logic Controller). This allows remote operation, real – time status monitoring (e.g., open/closed position feedback), and automated process control, fitting modern industrial automation needs. For example, in a power plant’s ash handling system, it can be programmed to open/close based on ash hopper levels, achieving unmanned operation.

Product Overview

III. Feature Description

1. Double – Gate Sliding Structure

The parallel sliding double – gate design ensures uniform force distribution during opening and closing. Unlike single – gate valves prone to jamming due to uneven particle accumulation, the double gates float slightly, self – aligning with the seats. This not only reduces mechanical wear but also enhances sealing reliability. When handling media with large particles (e.g., coal slime particles of 1 – 5mm), the gates can still close tightly, preventing leakage and pipeline blockages.

2. Ceramic Sealing Advantage

Ceramic materials offer outstanding wear and corrosion resistance. In power plant fly ash pipelines, where ash particles (with hardness around Mohs 5 – 7) continuously scour the valve, ceramic gates and seats maintain low wear rates. Compared to metal – sealed valves (which may leak after 3 – 6 months), ceramic – sealed ones can operate for 2 – 3 years without significant performance degradation, greatly reducing maintenance frequency and costs.

3. Sealing Compensation Mechanism

Integrated elastic compensation components (e.g., springs) ensure long – term sealing stability. As ceramic parts experience minimal wear over time or under pressure fluctuations, the springs automatically adjust the gate – to – seat distance, compensating for dimensional changes. This eliminates the need for frequent manual adjustments, ensuring the valve maintains “bubble – tight” sealing (conforming to API 598 standards) throughout its service life.

4. Streamlined Flow Path Design

The valve’s internal flow path is optimized for smooth media passage. The straight – through structure and polished inner walls (Ra ≤1.6μm) minimize flow resistance and prevent material accumulation. In slurry transport (e.g., mining tailings slurry with a density of 1.2 – 1.5g/cm³), this design reduces pipeline pressure loss, lowers energy consumption, and avoids blockages caused by sedimentation, ensuring continuous and efficient media transport.

IV. Manufacturing Process

1. Ceramic Component Production

  • Forming: High – purity alumina or zirconia powder is mixed with binders and formed using isostatic pressing. This process ensures uniform density and precise dimensions of ceramic blanks, laying the foundation for subsequent processing.
  • Sintering: The blanks are sintered at high temperatures (1600 – 1800℃ for alumina; higher for zirconia). Sintering densifies the ceramic structure, enhancing hardness and wear resistance. After sintering, ceramic parts have a density of ≥3.6g/cm³, ensuring excellent mechanical properties.
  • Precision Machining: Sintered ceramic parts undergo CNC grinding and lapping, achieving a surface roughness of Ra ≤0.8μm and a flatness tolerance of ≤0.01mm. This precision ensures a perfect seal between the gate and seat, minimizing leakage risks.

2. Metal Part Fabrication

  • Casting: The valve body and other metal components are cast using resin sand casting. This method reduces internal defects like pores and sand inclusions, ensuring structural integrity. After casting, parts undergo heat treatment (e.g., annealing) to eliminate internal stresses, preventing deformation during machining and operation.
  • Machining: Key metal parts (e.g., stem, flange) are machined using CNC equipment, ensuring dimensional accuracy (e.g., flange dimensions conform to ANSI B16.5 standards). The stem’s surface is treated (e.g., nitriding) to enhance corrosion and wear resistance, improving service life.

3. Assembly and Testing

  • Assembly: Ceramic components are bonded to metal gates using high – temperature – resistant adhesives and mechanical fastening. This dual – fixation method ensures ceramic parts do not detach under vibration or pressure changes. The pneumatic actuator is assembled with precision, ensuring smooth actuation force transmission.
  • Testing:
    • Pressure Test: Conducted at 1.5 times PN (2.4MPa) for the shell and 1.1 times PN (1.76MPa) for the sealing performance. The valve must withstand pressure for 30 minutes without leakage, verifying structural and sealing reliability.
    • Performance Test: Includes 1000+ cycle actuation tests to ensure the pneumatic system and mechanical structure operate stably. Ceramic parts are inspected for wear and cracking, guaranteeing product quality before leaving the factory.

Valve Details

V. Product Advantages

1. Extended Service Life

The combination of ceramic sealing and a robust metal structure significantly extends service life. In abrasive media applications, it outperforms traditional metal – sealed valves by 5 – 8 times. For example, in a coal – fired power plant’s ash discharge system, replacing a metal valve (with a 3 – month service life) with TIANYU’s ceramic valve reduces valve replacement frequency from 4 times a year to once every 2 – 3 years, cutting maintenance costs and downtime.

2. Reliable Sealing Performance

The double – gate structure, ceramic sealing, and elastic compensation mechanism ensure long – term “zero leakage” (or minimal leakage meeting API 598 Class B standards). This is critical for handling toxic, flammable, or environmentally hazardous media (e.g., chemical plant waste acid). Reliable sealing prevents media leakage, protecting the environment and ensuring operator safety.

3. High Efficiency and Low Energy Consumption

The streamlined flow path and fast pneumatic actuation improve system efficiency. Reduced flow resistance lowers pump energy consumption (by 5 – 10% in some cases). Fast actuation enables timely process adjustments, such as quickly closing the valve to prevent pipeline over – filling during slurry transport, avoiding spills and ensuring production continuity.

4. Strong Adaptability

With a wide temperature range (- 20℃ to 300℃, extendable to 500℃ with special ceramics) and compatibility with various media (abrasive, corrosive, high – viscosity), the valve suits diverse industrial environments. From power plant ash handling (high – temperature, abrasive) to chemical plant corrosive fluid discharge (acidic/alkaline), it provides stable performance, eliminating the need for multiple valve types and simplifying inventory management.

Application

VI. Product Applications

1. Power Generation Industry

  • Ash Handling Systems: Used in coal – fired power plants for fly ash, bottom ash, and slag slurry discharge. The ceramic valve resists ash particle erosion, ensuring smooth ash transport and storage. For example, in a 600MW power plant, it can be installed in the ash conveyor pipeline between the electrostatic precipitator and the ash storage, preventing blockages and ensuring efficient ash removal.
  • Desulfurization and Denitrification Systems: Controls the flow of corrosive media like limestone slurry and desulfurization wastewater. The valve’s corrosion – resistant materials (stainless steel body + ceramic sealing) withstand the acidic environment, ensuring long – term operation of desulfurization equipment.

2. Mining and Metallurgy Industry

  • Slurry Transport: Manages mineral slurry (e.g., copper, iron ore slurry) transport in concentrators and tailings disposal systems. The valve’s wear – resistant ceramic parts and anti – blockage design ensure stable slurry flow, preventing pipeline shutdowns due to valve failures.
  • Ore Dressing Processes: Controls the addition of chemicals (e.g., flotation reagents) and the discharge of concentrate slurry. Precise flow control and corrosion resistance meet the strict requirements of mineral processing, improving product quality and recovery rates.

3. Chemical and Petrochemical Industry

  • Corrosive Fluid Discharge: Handles the discharge of acidic/alkaline wastewater, chemical slurries, and hazardous media. The valve’s stainless steel body and ceramic sealing ensure corrosion resistance and zero leakage, complying with environmental protection regulations. For example, in a petrochemical plant’s wastewater treatment unit, it can safely discharge acidic wastewater without leakage, protecting the surrounding environment.
  • Powder and Granule Handling: Controls the flow of chemical powders (e.g., catalyst, pigment powder). The streamlined flow path and ceramic sealing prevent powder accumulation and leakage, ensuring accurate material metering and transport.

4. Environmental Protection and Wastewater Treatment

  • Sludge Treatment: Manages sludge transport and discharge in sewage treatment plants. The valve’s wear – resistant and anti – clogging features handle high – viscosity, particle – laden sludge, ensuring smooth operation of sludge dewatering and disposal systems.
  • Waste Incineration: Controls the flow of incinerator ash and flue gas treatment media (e.g., activated carbon slurry). The valve withstands high – temperature and abrasive media, ensuring stable operation of waste – to – energy plants.
TIANYU DN100 PN16 Pneumatic Ceramic Discharge Double Gate Valve integrates ceramic wear resistance, pneumatic efficiency, and reliable sealing. Ideal for abrasive/corrosive media in power, mining, and chemical sectors, it ensures long – term stable operation.

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