**Core Tip: The soda ash industry is a crucial sector in the chemical raw materials industry, with soda ash serving as a fundamental industrial material that supports national economic development. China's soda ash products hold a strong competitive advantage in the global market. During the "Tenth Five-Year Plan" and beyond, the state has prioritized organic raw materials, synthetic materials, new technologies, fine chemicals, and traditional "two bases" as key targets for the chemical industry's 10th Five-Year Plan and the 15-year development strategy.**
Currently, the production of soda ash in China primarily relies on the ammonia-soda process. This method uses salt and limestone as main raw materials, with ammonia acting as an auxiliary component. In the brine refining stage, magnesium (Mg²âº) and calcium (Ca²âº) ions react to form Mg(OH)â‚‚ and CaCO₃, which create salt cement. This cement is mixed with distillation waste liquid and discharged through clarification or filter press, forming waste liquid L1.
Raw saltwater (or seawater) is dissolved into crude brine, which is then refined to remove impurities like Ca²⺠and Mg²âº. The purified brine absorbs ammonia in an ammonia absorption tower, creating ammonia brine. This brine is then introduced into a carbonation tower where it reacts with COâ‚‚ to produce a suspension of sodium bicarbonate (NaHCO₃). After vacuum filtration, the resulting filter cake becomes the soda ash product. The COâ‚‚ gas produced during calcination is recycled back into the carbonation tower.
The mother liquor from this process is sent to an ammonia distillation tower for ammonia recovery. The recovered ammonia is then used to prepare new ammonia brine for the next cycle. In the alkali method, ammonia and COâ‚‚ are combined with salt to produce both soda ash and ammonium chloride simultaneously. The process involves carbonization of ammonia liquor II and COâ‚‚ in the carbonation tower, followed by vacuum filtration. The filter cake is then calcined to produce soda ash, while the remaining mother liquor is further processed to recover ammonium chloride.
These production processes involve long flow paths, high-temperature mother liquor, and complex compositions, including ammonia, high chloride content, and small amounts of calcium and magnesium solids. This leads to severe corrosion and wear on equipment, pipes, and valves, increasing maintenance frequency and operational instability. Therefore, improving the corrosion and wear resistance of equipment is essential for safe and stable operation.
Valves, as critical components in fluid control, are especially vulnerable to damage. Zirconium ceramic ball valves offer excellent performance with minimal leakage, erosion, and long service life. Traditional metal valves have been in use for over a century, but their limitations in harsh environments—such as high wear and strong corrosion—have led to frequent failures and leaks, affecting system stability.
In response, engineering ceramics have emerged as a revolutionary alternative. These materials, known for their high hardness, strength, wear resistance, and corrosion resistance, were initially developed for military and aerospace applications. By the 1990s, they began to be applied in the valve industry, gaining widespread recognition.
TZP (tetragonal zirconia polycrystal) ceramic, commonly used in valves, is made from zirconium oxide. It undergoes advanced manufacturing techniques such as spray granulation, isostatic pressing, sintering, and precision machining, significantly improving its toughness and strength. Often referred to as "ceramic steel," TZP offers high hardness, wear resistance, self-lubricating properties, low thermal conductivity, and an ultra-smooth surface finish (Ra up to 0.01 μm), making it an ideal replacement for metal valves.
Ceramic ball valves combine the advantages of structural ceramics with the efficiency of ball valves. They excel in sealing, anti-clogging, and flow control, with a simple, unobstructed flow path and quick opening/closing. Their ability to handle high pressure differentials makes them suitable for various industries, including petrochemicals, mining, power generation, pharmaceuticals, and papermaking.
In the soda ash industry, ceramic ball valves effectively address the challenges of high corrosion and solid particle wear, especially in brine and distillation processes. They outperform traditional corrosion-resistant alloys, making them the most ideal choice for such applications.
Stainless steel hard-seal ceramic ball valves are the only ones in the world that meet the VI-level sealing standard. The KW series of ceramic ball valves utilize structural ceramics with superior corrosion and wear resistance, designed based on advanced German engineering principles. They are manufactured according to international standards such as GB, DIN, JIS, and API. These valves provide excellent performance in high-temperature, corrosive, and abrasive environments, significantly extending their service life and improving the safety and stability of the system.
They reduce labor intensity, lower maintenance costs, and offer good economic value. As an ideal substitute for imported high-end valves, they have great potential for promotion and application. Currently, they are widely used in desulfurization systems, playing a positive role in preventing leaks and supporting environmental protection.
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