Sliding valve for the transport of coal in the metal industry
A leading company in the metal industry was looking for a reliable solution for sealing and controlling material flows. The medium involved a mixture of fine dust and small lumps of coal, flowing through the system at temperatures around 300 °C and pressures of about 200 mbar.
Challenge
The old valves often jammed due to accumulation of dust and wear from sharp carbon particles. The problem was exacerbated by the high temperature and pressure in the system. In addition, the valves were not overhaulable, which meant that when failures occurred, the entire valve had to be replaced each time. This resulted in:
- High replacement and maintenance costs
- Regular unplanned downtime
- Loss of production capacity and efficiency
Approach / Solution
After analyzing the process conditions, a DN600 gate valve with pneumatic actuator was chosen. In cooperation with our supplier Lohse GmbH, a solution was developed that fully met the requirements of the process. Important features:
- Wear-resistant materials resistant to sharp carbon particles at high temperatures
- Flush connections that prevent accumulation of dust in dead spaces
- Modular, overhaulable design, requiring only wear parts to be replaced
- Reliable seal that prevents leakage even at ±300 °C and 200 mbar
Results
The implementation of the new gate valve provided immediate benefits:
- Up to 90% fewer failures in the first six months
- Lower maintenance costs as overhaul is possible instead of complete replacement
- Higher process availability, through fewer unplanned downtimes
- Reliable operation under extreme conditions (300 °C, 200 mbar)
Conclusion / Lessons learned
This case proves that a carefully chosen and robustly designed gate valve can make the difference in challenging process conditions. Whereas the old valve had to be completely replaced each time, the new DN600 with pneumatic actuator and flush connections offers a maintenance-friendly and durable alternative that can withstand high temperatures, dust and abrasive media.
Our expertise
In addition to supplying components, we are happy to make our expertise available. Together with our customers and partners, such as Lohse GmbH, we search for the most suitable solution for their specific process. Thanks to our experience in heavy industrial applications, we support companies in improving their reliability, efficiency and sustainability.
What products were used
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