• Ceramic Lined Ceramic Ball Valve  Product System 1
Ceramic Lined Ceramic Ball Valve  Product

Ceramic Lined Ceramic Ball Valve Product

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1000 pc
Supply Capability:
3000 pc/month

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Application:

 

Applied in any media, expect HF (Hydrofluoric Acid) or glass solution, with max. temperature up to 500°C or max pressure 5.0 Mpa, such as high corrosion, high attrition and middle pressure.

 

Structural: 3-part flange type float ball valve Flange standards follow DIN/ANSI/API/JIS

 

l Excellent wear-proof property of ceramic enables this valve have high reliability and prolonged lifespan which is 2-4times as much as Titannium Alloy and Monel Metal valve.

 

Elastic O ring fit between metal part and ceramic part makes the whole part high sealing capacity, unables the two parts blind, and avoid the ball broken.

 

Valve steams are selected among 316/316L stainless steel, HC alloy, Monel Alloy, structural ceramic.

 

Completely symmetric design ensures dual leak-proof and two-direction usage to prolong its lifespan to twice.

 All parts that connect the medium are made of structural ceramics with extremely high chemical stability and hardness (HRC 90), which is only inferior to diamond. So the valve features exceedingly high wear-proof capability, corrosion resisting, enduring capability, good heat insulation, small thermal expansion.

 

        The valve is unique in granule medium of high hardness, or erosive soft granule and is the only choice for such medium. They are wisely used in FDG System, Slag system and LNCFS in power plant, saline water and distilling processes in alkali works, paper pulp system in paper mill, and so on.

 

       The ball is processed by advanced polishing equipment and technology that can ensure high circularity, good surface quality,.

     The self-lubricating capability of ZrO2, ensure the good sealing performance between the ball and its seat. It is thoroughly free from the defects of easy leakage, big torque, non-resistance sealing surface comparing with metal sealing valve.

 

ZrO2 Composition Chart of MZ Ceramic Ball Valve

 

NO.

Physical Property

Parameter

1

Crystal

>85% cubic,

the rest monoclinic

2

Lg. Loss

0.8%-1.0%

3

Average

0.4-0.7um

4

Apparent Density

>0.4g/cc

5

ZrO2 Purity

>99.95%

6

Tapped Density

>0.8g/cc

 

Q:What are the key characteristics of monolithic refractories for electric arc furnace applications?
Monolithic refractories for electric arc furnace applications have several key characteristics that make them suitable for the harsh conditions and high temperatures encountered in these environments. Firstly, monolithic refractories offer excellent thermal shock resistance. Electric arc furnaces operate at extremely high temperatures, and the rapid temperature changes that occur during the melting and refining processes can cause significant thermal stress. Monolithic refractories are designed to withstand these thermal shocks without cracking or spalling, ensuring the longevity and performance of the lining. Secondly, monolithic refractories have high resistance to chemical attack. Electric arc furnaces involve the melting and refining of various metals and alloys, which can create highly corrosive atmospheres. Monolithic refractories are formulated with chemically inert materials and additives that provide resistance to the corrosive effects of molten metals and slag, protecting the lining from chemical degradation. Another important characteristic of monolithic refractories for electric arc furnace applications is their high refractoriness. Refractoriness refers to the ability of a material to retain its strength and integrity at high temperatures. Electric arc furnaces typically operate at temperatures above 1500°C, and monolithic refractories are designed to withstand these extreme conditions without significant loss of properties or degradation. Furthermore, monolithic refractories offer good thermal conductivity. This property allows for efficient heat transfer throughout the lining, ensuring uniform heating and melting of the charge material. It also helps to minimize hot spots and thermal gradients, which can lead to uneven wear and premature failure of the lining. Lastly, monolithic refractories are known for their ease of installation and repair. Unlike traditional brick or block refractories, monolithic materials can be cast, sprayed, or rammed into place, eliminating the need for complex masonry work. This not only saves time and labor but also allows for easy maintenance and repair of the lining, reducing downtime and improving overall furnace efficiency. In summary, the key characteristics of monolithic refractories for electric arc furnace applications include excellent thermal shock resistance, high chemical resistance, high refractoriness, good thermal conductivity, and ease of installation and repair. These properties make monolithic refractories ideal for withstanding the harsh conditions and demanding requirements of electric arc furnace operations.
Q:What are the key properties of ramming mixes used for monolithic refractory installations?
The key properties of ramming mixes used for monolithic refractory installations include high density, good flowability, high strength, excellent thermal shock resistance, chemical resistance, and low porosity. These properties ensure the ramming mix can be compacted easily during installation, withstand high temperatures without cracking, and resist chemical attacks from molten metals or corrosive gases. Additionally, low porosity helps to minimize heat loss and enhance the overall performance and longevity of the refractory lining.
Q:What are the factors to consider when selecting monolithic refractories for specific applications?
When selecting monolithic refractories for specific applications, there are several factors that need to be considered. These factors include the operating temperature, chemical environment, mechanical stress, and the desired performance characteristics of the refractory material. The operating temperature is a crucial factor to consider as different monolithic refractories have different temperature limits. It is important to choose a refractory material that can withstand the specific temperature range of the application without suffering from thermal spalling or degradation. The chemical environment in which the refractory will be exposed is another crucial factor. Different applications may involve exposure to various chemicals, acids, alkalis, or gases. It is essential to select a monolithic refractory that is chemically resistant to the specific environment to ensure prolonged durability and performance. Mechanical stress is also an important consideration when selecting monolithic refractories. Some applications may involve high mechanical stress such as abrasion, impact, or thermal shock. It is crucial to choose a refractory material that can withstand these stresses without cracking or failure. The desired performance characteristics of the refractory material should also be taken into account. This includes factors such as thermal conductivity, thermal expansion, density, and strength. The application requirements will dictate the specific performance characteristics needed, and the refractory material should be chosen accordingly. Other factors to consider include installation method, availability, cost, and maintenance requirements. Some monolithic refractories may require specialized installation techniques, while others may be more readily available and cost-effective. Additionally, the maintenance requirements of the refractory material should be considered to ensure ease of upkeep and longevity. Overall, selecting the right monolithic refractories for specific applications requires careful consideration of factors such as operating temperature, chemical environment, mechanical stress, desired performance characteristics, installation method, availability, cost, and maintenance requirements. By considering these factors, one can choose the most suitable refractory material that will provide optimal performance and durability in the given application.
Q:Can monolithic refractories be used for the lining of ladle refining furnaces and VOD converters?
Yes, monolithic refractories can be used for the lining of ladle refining furnaces and VOD (Vacuum Oxygen Decarburization) converters. Monolithic refractories are versatile materials that can be shaped and installed in various applications, including high-temperature environments like ladle refining furnaces and VOD converters. Monolithic refractories are composed of a single, homogeneous material, which makes them easy to install and repair. They can be either cast or gunned in place, providing flexibility in lining design and installation. The lining of ladle refining furnaces and VOD converters requires materials that can withstand high temperatures, chemical reactions, and mechanical stresses. Monolithic refractories, with their excellent thermal shock resistance and resistance to chemical attack, are well-suited for these demanding applications. In ladle refining furnaces, monolithic refractories are used to line the ladle, which holds and processes molten metal. These refractories help maintain the desired temperature and protect the ladle from the corrosive effects of molten metal and slag. They also provide insulation to minimize heat loss and improve energy efficiency. VOD converters are used in the steelmaking process to reduce the carbon content of molten steel. Monolithic refractories are used to line the converter's vessel and maintain the necessary temperature for the decarburization reaction. They also provide protection against the corrosive effects of molten metal and slag, ensuring the longevity and performance of the converter. Overall, monolithic refractories offer excellent properties for the lining of ladle refining furnaces and VOD converters. Their versatility, ease of installation, and resistance to high temperatures and chemical attack make them an ideal choice for these critical applications in the steel industry.
Q:How are monolithic refractories different from conventional refractories?
There are several ways in which monolithic refractories differ from conventional refractories. To begin with, conventional refractories are typically constructed using pre-formed shapes like bricks or tiles, whereas monolithic refractories are shapeless and can be installed through casting, gunning, or ramming. This allows for greater design and installation flexibility since monolithic refractories can be molded to fit any complex shape or size requirement. Additionally, monolithic refractories possess a higher level of thermal shock resistance compared to conventional refractories. This means that they can withstand rapid temperature changes without cracking or spalling. This characteristic is especially significant in applications where the refractory is exposed to extreme temperature fluctuations, such as in furnaces or kilns. Moreover, monolithic refractories exhibit superior corrosion resistance, making them more suitable for environments with acidic or alkaline conditions. They are also renowned for their exceptional mechanical strength and resistance to abrasion, making them ideal for situations where the refractory experiences high mechanical stress or wear. Lastly, monolithic refractories offer enhanced energy efficiency due to their lower thermal conductivity. Consequently, they can retain heat more effectively, resulting in reduced energy consumption and cost savings. In summary, the key distinctions between monolithic refractories and conventional refractories lie in their installation methods, thermal shock resistance, corrosion resistance, mechanical strength, and energy efficiency. These factors establish monolithic refractories as the preferred choice in numerous industrial applications where flexibility, durability, and performance are of utmost importance.
Q:How are monolithic refractories manufactured?
Monolithic refractories are manufactured using a specific process that involves several steps. The first step is the selection and preparation of raw materials. These raw materials usually include aggregates, binders, and additives. Aggregates are chosen based on their chemical and physical properties, while binders are used to hold the aggregates together. Additives are included to enhance specific properties of the refractory material. Once the raw materials are selected, they are mixed together in precise proportions to create a homogeneous mixture. This mixture is then blended using various techniques such as dry or wet mixing, depending on the desired characteristics of the final product. After blending, the next step is shaping the refractory material. This can be done through several methods such as casting, gunning, ramming, or spraying. Each method is chosen based on the specific application and requirements of the refractory. Once the refractory material is shaped, it undergoes a curing process. This process involves drying the material at a controlled temperature to remove any excess moisture and allow for the development of desired properties. Finally, the cured refractory material is fired in a kiln at high temperatures. This firing process helps to further strengthen the refractory and enhance its resistance to heat and other harsh conditions. Overall, the manufacturing of monolithic refractories involves careful selection and preparation of raw materials, precise blending, shaping, curing, and firing processes. This ensures the production of high-quality refractory materials that can withstand the extreme conditions found in various industrial applications.
Q:What are the challenges in recycling monolithic refractories?
There are several challenges in recycling monolithic refractories that make the process more complex compared to other materials. Firstly, monolithic refractories are designed to withstand high temperatures and harsh conditions, making them highly resistant to wear and tear. This durability also poses a challenge in the recycling process, as it requires specialized techniques and equipment to break down and separate the refractory material. Secondly, monolithic refractories often contain various additives and binders, such as clay, cement, and other organic compounds, which can complicate the recycling process. These additives may need to be removed or separated from the refractory material before it can be recycled effectively. Additionally, monolithic refractories can be contaminated with other materials, such as metal oxides, slag, and impurities, during their service life. These contaminants can affect the quality and properties of the recycled refractory material, requiring thorough cleaning and purification processes. Moreover, the logistics involved in collecting and transporting monolithic refractories for recycling can be challenging. Refractories are often used in large quantities in industrial settings, and their removal and transportation can be costly and time-consuming. Furthermore, finding suitable recycling facilities with the necessary equipment and expertise to handle monolithic refractories can be limited, especially in certain regions. Lastly, economic factors play a role in the challenges of recycling monolithic refractories. The cost of recycling and processing the refractories may not always be financially viable compared to using virgin materials. This can discourage companies from investing in recycling programs and contribute to the lower demand for recycled refractory materials. Overall, the challenges in recycling monolithic refractories mainly stem from their durability, complex composition, contamination, logistics, and economic considerations. However, advancements in technology and increased awareness of the environmental benefits of recycling may help overcome these challenges and promote the sustainable reuse of refractory materials.
Q:How do monolithic refractories withstand thermal cycling in the iron and steel industry?
Monolithic refractories are designed to withstand thermal cycling in the iron and steel industry due to their unique composition and properties. These refractories are made from a single, continuous material, unlike traditional refractory bricks that are made by stacking individual bricks together. One of the main reasons monolithic refractories are able to withstand thermal cycling is their ability to expand and contract without cracking or damage. This is due to their high thermal shock resistance, which is a measure of their ability to withstand rapid temperature changes. Monolithic refractories are specially formulated to have low thermal conductivity, allowing them to resist the transfer of heat and minimize thermal gradients within the material. In addition, monolithic refractories have excellent thermal stability, which means they can maintain their structural integrity and mechanical strength even at high temperatures. This is crucial in the iron and steel industry, where temperatures can reach extreme levels. The refractories are able to withstand repeated heating and cooling cycles without undergoing significant structural changes or degradation. Furthermore, monolithic refractories have good corrosion resistance, which is important in an environment where they come into contact with molten metal and various chemical agents. Their composition and special additives help to protect the refractory material from chemical attack, preventing erosion and prolonging their lifespan. The manufacturing process of monolithic refractories allows for easy installation and repair, as they can be applied as a liquid or a semi-liquid mixture. This reduces the risk of joints or weak points that could lead to thermal stress or failure during thermal cycling. Overall, the combination of high thermal shock resistance, low thermal conductivity, excellent thermal stability, corrosion resistance, and easy installation makes monolithic refractories highly durable and capable of withstanding the severe thermal cycling conditions in the iron and steel industry.
Q:How do monolithic refractories impact the overall productivity of iron and steel operations?
The overall productivity of iron and steel operations is greatly enhanced by monolithic refractories. These refractories are specifically designed to withstand extreme temperatures, chemical reactions, and mechanical stress that occur during production. One important way that monolithic refractories impact productivity is by reducing downtime and increasing operational efficiency. These refractories have high thermal conductivity and are resistant to thermal shock, allowing them to maintain stable temperatures within the furnace. This prevents sudden temperature fluctuations that can lead to equipment failure and production delays. As a result, the production process can continue uninterrupted, leading to increased productivity. Furthermore, monolithic refractories offer superior corrosion resistance, preventing the erosion and degradation of furnace linings. This resistance to chemical attacks from molten metals and slag helps prolong the lifespan of the refractory lining, reducing the need for repairs and replacements. This leads to less downtime and higher productivity for iron and steel operations. Additionally, monolithic refractories enable faster installation and repair processes compared to traditional brick refractories. They have a fluid-like consistency that makes application and shaping easy, resulting in shorter installation and curing times. This quick turnaround time minimizes production interruptions during repairs or maintenance, further increasing overall productivity. Moreover, the use of monolithic refractories can optimize energy consumption in iron and steel operations. Their excellent insulation properties help retain heat within the furnace, reducing heat loss and energy waste. This improves energy efficiency and leads to cost savings, ultimately contributing to increased productivity and profitability. In conclusion, monolithic refractories have a significant impact on the productivity of iron and steel operations. Their ability to withstand extreme conditions, reduce downtime, resist corrosion, facilitate quick repairs, and optimize energy consumption all contribute to improved efficiency and productivity in the industry.
Q:What are the main challenges in designing the lining system with monolithic refractories?
Achieving proper installation is one of the primary difficulties in designing the lining system using monolithic refractories. Skilled labor and precise application techniques are required for the installation, which can involve casting, gunning, or shotcreting. The performance and longevity of the lining system can be compromised if any errors or inconsistencies occur during installation. Ensuring sufficient bonding between the monolithic refractories and the existing structure presents another challenge. To prevent delamination or separation of the refractory material from the underlying surface, proper adhesion is crucial. Factors like surface preparation, temperature differences, and mechanical stress can affect the strength of the bond, necessitating careful consideration during the design phase. The compatibility of monolithic refractories with different operating conditions also poses a challenge. Refractory materials are exposed to extreme temperatures, chemical reactions, and thermal cycling, which can result in degradation and failure. Designing a lining system that can withstand these conditions requires a thorough understanding of the refractory properties and the specific requirements of the application. Furthermore, selecting the appropriate monolithic refractory material for a given lining system is a significant challenge. There are various types of monolithic refractories available, each with its own advantages and disadvantages. When choosing the most suitable material for the application, factors like temperature range, chemical composition, thermal conductivity, abrasion resistance, and thermal shock resistance must be taken into account. Lastly, maintaining the integrity of the monolithic refractory lining system throughout its lifespan is challenging. Regular inspections, repairs, and maintenance are necessary to address issues such as cracks, erosion, or spalling. Developing a comprehensive maintenance plan and ensuring access to skilled personnel for repairs are crucial aspects of designing a successful lining system with monolithic refractories.

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