Valve, a small but crucial component of a fertilizer company's compressor, plays a significant role in both production costs and energy efficiency. Despite its size, it has become a major challenge for many companies, as it not only increases operational expenses but also hinders efforts to reduce energy consumption and waste.
Reporters found that some nitrogen fertilizer companies using coal as raw materials face issues due to the presence of dust, tar, and other impurities in the compressed gas. These contaminants tend to accumulate on the internal surfaces of the gas valves, causing increased wear, poor sealing, and air leakage. As a result, the valves often fail prematurely, with their actual service life being less than 1% of the ideal duration. Moreover, when valves become clogged, frequent shutdowns are required for cleaning, which leads to wasted raw materials, reduced output, and higher energy consumption. According to one nitrogen fertilizer plant, the loss from a single 57 cubic meter per minute compressor can reach between 2,400 to 2,500 yuan. This is just the direct cost, and there are even greater indirect losses due to machine downtime and maintenance.
However, companies like Hubei Yihua Group have found a solution. After extensive trials, they opted for an anti-fouling gas valve manufactured by Wenzhou Blaine Compressor Manufacturing Co., Ltd. This valve, featuring independent intellectual property rights, is designed to function effectively in harsh gas environments containing dust, tar, and activated carbon. The valve plate is made from special engineering plastics, and the surface is coated with an anti-fouling layer, preventing dirt from sticking. This significantly reduces wear and eliminates issues like air leakage and run-off. Energy consumption during production has dropped by 3% to 8%, and the valve’s lifespan has increased more than fivefold compared to traditional models. Additionally, the need for frequent cleaning and maintenance has been eliminated, reducing downtime and saving costs.
Henan Lyuyu Chemical Co., Ltd. shared similar experiences. Before switching to the anti-fouling valve, the company had to clean its 11 compressors every 10 to 15 days, which was time-consuming and disrupted production. After installing the new valve on two compressors in September 2006, the results were impressive. The compressors ran smoothly without leaks or dirt buildup, and after three months, no cleaning was needed. The company estimated that if they had continued using the old valves, they would have faced over 20 shutdowns, costing more than 100,000 yuan. If all compressors were upgraded, the savings would be substantial.
Fuzhou Yaolong Chemical Group also adopted the anti-fouling valve. Initially skeptical about domestic products, they decided to test it on a large compressor after seeing success stories from other companies. Since April 2006, the compressor has operated efficiently without any downtime, saving the company over 100,000 yuan in a year. They now plan to expand its use across other compressors.
Nitrogen fertilizer companies emphasize that there are few simple and effective solutions available for reducing costs and improving energy efficiency. They hope more companies will develop innovative products that meet their needs, compete in the market, and further optimize performance while lowering prices.
The anti-fouling gas valve produced by Wenzhou Blaine has recently received a national patent. The company is actively visiting clients and is ready to customize and improve the product based on specific customer requirements.
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