Background
The tail gas treatment working conditions in metallurgical and chemical industries (including oil refining & petrochemical, coking, spraying, etc.) are extremely harsh. The working medium is a high-temperature mixture of nitrogen and acrylic gas at 450℃, which is flammable, explosive and highly corrosive, and contains trace solid particles. Accordingly, the pipes and valves are required to deliver excellent temperature resistance, explosion protection, sealing performance and wear resistance.
Production lines are designed for long-term continuous operation. Conventional valves applied in high-temperature and explosion-prone scenarios suffer from high leakage risks, rapid seal failure, poor regulation accuracy, low automation level and short service life. These defects may easily lead to safety incidents, substandard tail gas treatment results and high operation & maintenance costs. Featuring outstanding high temperature resistance, explosion protection, metal hard sealing and intelligent regulation capabilities, the GRAT Hard-seal Explosion-proof Electric Control Butterfly Valve is perfectly tailored for the complex working conditions of tail gas treatment in metallurgical and chemical sectors, ensuring efficient and stable operation of VOCs mobile treatment units.
Key Challenges
- Insufficient Safety against High Temperature and Explosion The medium reaches up to 450℃ and is flammable and explosive. Ordinary valves have low explosion-proof grade and weak protection performance. They are prone to aging under high temperature, and electrical sparks may trigger explosion accidents.
- Poor Sealing Performance and Frequent Leakage The high-temperature corrosive mixed gas and trace solid particles tend to erode sealing surfaces. Traditional soft-seal valves are vulnerable to aging and damage, while metal-seal valves adopt unreasonable sealing structures with high leakage rates. This causes escape of harmful gas, environmental pollution and material waste.
- Low Flow Regulation Accuracy Precise control of gas flow is essential for tail gas treatment. Conventional valves present poor linearity of regulation and slow response, failing to adapt to fluctuating working conditions. As a result, the treatment efficiency is reduced and tail gas emissions fail to meet standards.
- Poor Adaptability for Automation & Maintenance Most traditional valves are manually operated without remote intelligent control functions. With complex structure and large size, they are difficult to install on VOCs mobile treatment units. Their assembly, disassembly and daily maintenance are complicated and costly.
Operation Condition
Product Name: GRAT Series Stainless Steel Electric Control Butterfly Valve (Hard-seal Explosion-proof Electric Modulating Butterfly Valve)
Application Scenarios: Tail gas treatment for oil refining & petrochemical, coking, chemical, spraying and other industries (VOCs mobile treatment units)
Working Medium: Mixed gas of nitrogen and acrylic gas (450℃)
Nominal Pressure: Class 150 (ASME B16.5)
Nominal Diameter: DN100 / DN150
Material: Valve core: SUS304; Valve body: SUS304 Stainless Steel
Sealing Type: Hard seal (Eccentric structure)
Connection Type: Wafer type
Operation Mode: Proportional regulation
Control Signal: 4-20mA
Power Supply: AC220V
Actuator: Explosion-proof electric actuator (equipped with LCD display; free switching between local/remote control and manual/automatic modes)
Explosion-proof Grade: Exd IIC T6
Ingress Protection Grade: IP68
Design Service Life: 5 years (Over 100,000 trouble-free operations)
Performance Result
1. Superior Explosion-proof Safety
With Exd IIC T6 explosion-proof grade and IP68 ingress protection rating, the valve is fully applicable to flammable, explosive media at 450℃. It effectively eliminates potential safety hazards caused by electrical sparks and high-temperature aging, and guarantees the safe operation of VOCs mobile treatment units.
2. Hard Seal with Zero Leakage
Combined with eccentric hard-seal structure and SUS304 stainless steel material, the valve resists erosion from high-temperature corrosive gas and abrasion by solid particles, achieving bidirectional zero leakage. It prevents the escape of harmful gas and fully complies with environmental emission standards.
3. High-precision Intelligent Regulation
Adopting 4-20mA proportional control signal and integrated intelligent explosion-proof actuator with fast response and excellent regulation linearity, the valve accurately adapts to fluctuating working conditions of tail gas treatment. It improves VOCs treatment efficiency and ensures qualified tail gas discharge.
4. Flexible Installation & Easy Maintenance
The wafer connection and compact structure well match the mobility requirements of VOCs mobile treatment units. The valve supports free switching between local/remote control and manual/automatic modes, and is compatible with DCS systems. It cuts down labor costs, enables easy assembly and disassembly, and minimizes downtime losses during maintenance.
5. Long Service Life & Stable Operation
Equipped with heat dissipation structure on the valve body and professional explosion-proof electric actuator, the valve features an actual average service life of over 7 years with more than 100,000 trouble-free operations. It greatly reduces valve replacement frequency and overall maintenance costs, and supports continuous and efficient operation of production lines.