Valve, a small but crucial component of a fertilizer company's compressor, plays a significant role in production efficiency. Despite its size, it not only contributes to the overall production cost but also hinders energy-saving and consumption-reduction efforts for many enterprises, becoming a major issue that companies face daily.
Reporters found that some nitrogen fertilizer companies using coal as raw materials encountered problems due to dust and tar in the compressed gas. These impurities tend to accumulate on the valve’s internal channels, leading to increased wear, poor sealing, gas leakage, and significantly shortened valve life—often just 1% of the expected lifespan. Moreover, when valves become clogged, they must be shut down for cleaning, causing frequent shutdowns and startups. This results in wasted raw materials, reduced output, and higher power consumption. According to one company, the loss from a single 57 cubic meter per minute compressor can reach between 2,400 and 2,500 yuan, with even greater indirect losses from machine downtime. Companies often need to clean their valves every ten days or so, which is a costly burden, especially for small and medium-sized enterprises.
However, Hubei Yihua Group Co., Ltd. and others have found a solution. After extensive testing, they opted for an anti-fouling gas valve manufactured by Wenzhou Blaine Compressor Manufacturing Co., Ltd. This valve, featuring independent intellectual property rights, performs well under harsh conditions containing dust, tar, and other contaminants. The valve plate is made of special engineering plastics, and the valve body is coated with an anti-fouling layer, preventing dirt from sticking. As a result, wear is significantly reduced, and issues like air leakage are resolved. Energy consumption in production has dropped by 3% to 8%, and the valve’s service life has increased fivefold compared to traditional models. Additionally, there’s no need for frequent cleaning, reducing downtime and maintenance costs. The company reports that this innovation has not only cut production costs but also simplified maintenance.
Henan Lyuyu Chemical Co., Ltd. shared similar experiences. Previously, they had to disassemble and clean their valves every 15 days, taking three to four days to clean 11 compressors. This was time-consuming and disrupted production. In September 2006, they tested the anti-fouling valve on two compressors. The results were impressive: the compressors ran smoothly without leaks or dirt buildup. Over three months, they didn’t experience any issues. The company estimated that if they had used 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.
Wuhan Fuyuan Chemical Co., which also replaced its gas valves, noted that previous valves needed cleaning every half a month and had a short lifespan, requiring replacement after just one month. The new anti-fouling valves have greatly improved durability, saving costs and boosting profits. Hubei Yihua Group reported that their old valves never lasted more than six months, while the new ones have been in use for 16 months without any issues.
This innovative valve has even gained attention from foreign machines. Fuzhou Yaolong Chemical Group’s nitrogen fertilizer plant uses U.S.-imported compressors, but the original valves performed poorly. Initially skeptical about domestic alternatives, the company decided to try the Wenzhou Blaine valve after seeing success stories from Chinese firms. Since installation in April 2006, the compressor has operated smoothly with no downtime or replacements. Over the past year, the company saved over 100,000 yuan and plans to expand the use of the product across other compressors.
Nitrogen fertilizer companies emphasize that few products on the market offer simple, effective ways to save energy and reduce costs. They hope more companies will develop such solutions, compete through the market, and continuously improve performance while lowering prices.
It is worth noting that the anti-fouling gas valve produced by Wenzhou Blaine has recently been granted a national patent. The company is actively visiting clients, ready to tailor improvements based on specific customer needs. This innovation marks a turning point for the industry, offering real benefits and long-term value.
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MIANYANG KEJIXIN TRADING CO., LTD , https://www.kjxnitrate.com