ceramic lined rotary valve systems

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SuperSeal Wear/Corrosion Resistant Systems for Rotary Valves Omegaslate SuperSeal Systems Limited 2 Chirk Close Forest Gate Kidderminster Worcestershire.DY10 1YG. UK. Tel: +44 (0) 1562 755 824 Fax: +44 (0) 1562 742 979 Web Address: www.omegaslate.com Omegaslate 2001 Wear Resistance Engineers

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Page 1: Ceramic Lined Rotary Valve Systems

SuperSeal Wear/Corrosion Resistant Systems for Rotary Valves

Omegaslate SuperSeal Systems Limited2 Chirk CloseForest GateKidderminsterWorcestershire.DY10 1YG. UK.

Tel: +44 (0) 1562 755 824 Fax: +44 (0) 1562 742 979Web Address: www.omegaslate.com

Omegaslate 2001

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Page 2: Ceramic Lined Rotary Valve Systems

About About OmegaslateOmegaslate SuperSealSuperSeal SystemsSystems

Omegaslate 2001

Omegaslate has upgraded and refurbished rotary valves and blowing seals, for more than 25 years ago.

Our upgrades are intended to maximise the operating life of rotary valves and blowing seals, no matter whom the manufacturer, by implementing improvements in design, engineering and materials.

This presentation endeavours to explain our technology.

Often valves are sent to us in a totally worn-out conditions, with holes in vanes, endplates and bodies; we also upgrade new valve.

On receipt of a valve, we strip and inspect it; prepare a condition report, supported by photographs, and include an upgrade specification, together with a detailed quotation.

The upgrading/refurbishing specification depends on the degree a sophistication required by the customer.

We use advanced ceramic materials to provide corrosion and abrasion resistance. These materials are bonded and mechanically fixed to the areas of the valve requiring protection.

Normally, we reduce the rotor diameter and length to take account for the ceramic lining thicknesses.

The most important aspect of our technology is our ceramic grinding facility. The ceramic components are fitted to the valve bore, endplates and rotor and then precision ground to size on a large rotary grinding machine s.

We have a variety of rotor and shaft sealing options available .

In all respects, we ensure that our systems provide the best possible cost effectiveness.

We have extensive, proven experience in solving extreme abrasion and corrosion problems associated with rotary valves and blowing seals.

Page 3: Ceramic Lined Rotary Valve Systems

Advantages of the Advantages of the SuperSealSuperSealLining SystemLining System

ó Low maintenance costs.ó Increased operating life.ó Increased plant efficiency.ó In very abrasive conditions it is possible to

save in the region of £35,000.00 per annum, per 380mm bore valve, over traditional non-ceramic refurbishing costs.

ó Reduced spares requirement.

Omegaslate 2001

Page 4: Ceramic Lined Rotary Valve Systems

Upgrading Rotary ValvesUpgrading Rotary Valves

ó Omegaslate upgrade and refurbish rotary valves and blowing seals for operation in extremely aggressive bulk minerals, metals and plastics handling and processing environments.

Omegaslate 2001

Page 5: Ceramic Lined Rotary Valve Systems

Rotary Valve BodyRotary Valve Bodyó Rotary valve bodies are

fitted with a 10mm thick CEROXALIDE Z3 and Z4, and RESILIDE

ceramic lining system.

ó The lining system is bonded and mechanically locked in position.

ó In order to provide a accurate and smooth bore , the ceramic lining system is precision diamond ground, after fitting, on large rotary grinding machines.

Omegaslate 2001

Page 6: Ceramic Lined Rotary Valve Systems

End PlatesEnd Plates

ó Depending on the size of the valve, 6mm or 12mm thick ceramic linings are bonded to the endplates.

ó The ceramic linings are diamond ground across the wear face and on the O/D to ensure an accurate fit inside the ceramic bore lining.

Omegaslate 2001

Page 7: Ceramic Lined Rotary Valve Systems

RotorsRotorsó The steel rotors are

reduced in diameter and length to accommodate the bore and endplate lining systems.

ó Ceramic secondary seals are fitted on the ends of the rotor and diamond ground

ó Ceramic protection is fitted to the parts of the rotor shaft that rotate in the stuffing boxes.

Omegaslate 2001

Page 8: Ceramic Lined Rotary Valve Systems

Heavy Duty Rotors with Heavy Duty Rotors with Ceramic Inserted VanesCeramic Inserted Vanes

Omegaslate 2001

Page 9: Ceramic Lined Rotary Valve Systems

Rotor Vane Sealing Rotor Vane Sealing Blade OptionsBlade Options

ó CEROXALIDE Z3 and Z4tm

alumina Ceramic, RESILIDEtm , tungsten carbide ceramic, and hardened steel blades can be fitted to the rotor vanes.

Omegaslate 2001

Page 10: Ceramic Lined Rotary Valve Systems

Omegaslate 2001

This is a rotary valve with a 670 mm diameter x 631 mm long bore, used for handling grain.

The cast iron bore is fitted with a 10 mm thick, diamond ground, 99.7% (CEOXALIDE Z4 tm) lining system.

The rotor is fitted with 12 mm thick 95% diamond ground alumina ceramic closed rotor end seals and 6 mm thick adjustable hardened steel blades.

The rotor clearance is 0.15 mm to 0.20 mm.

Page 11: Ceramic Lined Rotary Valve Systems

Omegaslate 2001

This is a rotary valve with a 320 mm diameter x 500 mm long bore, used for handling burner dust in the wood industry.

The fabricated steel bore is fitted with a 10 mm thick, diamond ground, 99.7% (CEOXALIDE Z4 tm) lining system.

The rotor is fitted with 25 mm thick 95% diamond ground alumina ceramic closed rotor end seals and 12 mm thick 95% alumina ceramic vane sealing blades.

The rotor clearance is 0.15 mm to 0.20 mm.

Page 12: Ceramic Lined Rotary Valve Systems

Rotor Rotor Seal OptionsSeal Optionsó Normal flexible gland packing

can be used for the stuffing boxes.

ó RESILIDE

air purge seals can be used in extremely abrasive applications.

ó Ceramic mechanical seals can be used in abrasive powder and grit applications.

ó Rubber lip seals can be used when handling fibrous materials, such as saw dust

Omegaslate 2001

Page 13: Ceramic Lined Rotary Valve Systems

RotofeedersRotofeeders

Omegaslate 2001

This 650 mm bore Roto-FeederIs fully lined with 12 mm thick, fully diamond ground, 99.7% alumina ceramic.

The rotor runs with a rotor clearance of 0.15 mm

Page 14: Ceramic Lined Rotary Valve Systems

Approximate Relative Life of Approximate Relative Life of Wear Wear Resistant MaterialsResistant Materials

200

90

3010 3 3 3 2 1

020406080

100120140160180200

RE

SIL

IDE

CE

RO

XA

LID

EZ4

CE

RO

XA

LID

EZ3 Nitr

ide

Bon

ded

SiC

Cas

t Bas

alt

Ni-h

ard

Har

d fa

cing

Tugs

ten

coat

ings

Cas

t iro

n

Rel

ativ

e Li

fe

Omegaslate 2001

Page 15: Ceramic Lined Rotary Valve Systems

Heat Transmission Properties of Heat Transmission Properties of Wear/Corrosion Resistant Materials.Wear/Corrosion Resistant Materials.

200

90 8871

40 35 33 2818 15

0

20

40

60

80

100

120

140

160

180

200

RES

ILID

E

SIN

TER

ED S

iC

TUN

GST

ENC

ARBI

DE

LEAD

BR

ON

ZE

NI-H

ARD

CER

OXA

LID

E Z4

SILI

CO

N N

ITR

IDE

CER

OXA

LID

E Z3

18/2

MAR

TIN

ISTI

CST

EEL

STEL

LITE

1

Ther

mal

exp

ansi

on c

oeffi

cien

t (K

-1X

10-6

)

Omegaslate 2001