**Core Tip:** The soda ash industry plays a crucial role in the chemical raw materials sector, serving as a fundamental industrial material that supports national economic development. China's soda ash products hold a strong competitive advantage in the international 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 majority of China’s soda ash is produced using the ammonia-soda process. This method uses salt and limestone as primary raw materials, with ammonia acting as an auxiliary agent. In the brine refining stage, magnesium and calcium ions react to form magnesium hydroxide and calcium carbonate, creating salt cement. This cement is then 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 the ammonia absorption tower, producing ammonia brine. This ammonia brine enters the carbonation tower, where it reacts with carbon dioxide to generate a suspension of sodium bicarbonate. After vacuum filtration, the resulting filter cake is the soda ash product, while the carbon dioxide gas from calcination is recycled back into the carbonization tower. The mother liquor from this process is sent to the ammonia distillation tower for ammonia recovery, which is then used again in the ammonia absorption tower.
The alkali method produces both soda ash and ammonium chloride in parallel. Ammonia liquor II and carbon dioxide are carbonized in the carbonation tower to produce a suspension of NaHCO₃. After vacuum filtration, the filter cake is calcined to become soda ash, while the mother liquor is processed further. For ammonium chloride production, the mother liquor absorbs ammonia, exchanges heat, and precipitates ammonium chloride crystals in a crystallizer. Further processing involves adding salt and heat transfer to continue precipitation, ultimately yielding ammonium chloride.
These processes involve long flow paths, high-temperature mother liquor, and complex compositions, including ammonia, high chloride content, and solid particles like calcium and magnesium. This leads to severe corrosion and wear on equipment, pipes, and valves, causing frequent failures and maintenance issues. Therefore, improving the corrosion and wear resistance of equipment is essential for safe and stable operation. As a critical component, the valve must withstand harsh conditions without leakage or damage.
Traditional metal valves have been widely used for over a century but struggle under high-corrosion and high-wear environments. Their short service life and leakage problems significantly affect system stability. Hence, there is an urgent need for innovation in valve materials, design, and manufacturing.
Engineering ceramic materials, such as TZP (tetragonal zirconia polycrystal), offer a promising alternative. These materials, known for their high hardness, strength, wear resistance, and corrosion resistance, were initially developed for military and aerospace applications. Over time, they found their way into industrial fields, including valves. TZP ceramic, derived from zirconium oxide, undergoes advanced processing to improve toughness and reduce brittleness, earning it the nickname "ceramic steel."
Ceramic ball valves combine the advantages of structural ceramics with the efficiency of ball valves. They excel in high-corrosion and high-solid-content environments, making them ideal for soda ash production. In particular, they outperform conventional corrosion-resistant alloys in brine and distillation processes. The stainless steel hard-seal ceramic ball valve meets the VI-level sealing standard, offering superior performance in terms of corrosion resistance, wear resistance, and high-temperature stability.
The KW series of ceramic ball valves, designed with advanced German engineering, are high-tech products that meet international standards like GB, DIN, JIS, and API. They significantly extend valve lifespan, enhance equipment safety, reduce maintenance costs, and improve operational efficiency. These valves are ideal replacements for imported high-end valves and have great potential for widespread adoption.
Currently, they are widely used in desulfurization systems, effectively preventing leaks and contributing positively to environmental protection.
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