[Case Study] Estimated annual savings of several tens of millions of yen with heating furnace switching valve, 2006 results.
Estimated annual savings of several tens of millions of yen from the heating furnace switching valve (2006 results).
Overview of Equipment This switching valve has a high switching frequency, occurring once every few seconds. Additionally, the exhaust gases are extremely hot, making the operating conditions quite harsh for the valve. Conventional valves (switching valves) have a lifespan of 1 to 2 years, during which operational failures frequently occurred. The cause was dust and tar entering the gap between the body and shaft of the fuel gas switching valve and exhaust gas switching valve, causing them to stick. As a result, there was a decrease in production efficiency, and in some cases, line stoppages occurred. Moreover, not only the switching valve itself but also the drive unit (air cylinder) frequently experienced failures, leading to a loss of functionality. Due to the necessity of regularly disassembling, cleaning, and replacing these switching valves (during each repair), the maintenance costs became quite substantial. 1. Operational failures of the valve due to dust and tar ingress 2. Operational failures due to drive unit (air cylinder) malfunctions 3. Loss of raw material costs due to poor sealing of the valve 4. Burden of labor and costs associated with disassembly and cleaning
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1. Change to NBS-made uniflow valve. 2. Provide a dust seal structure (at two locations). 3. Development of low-torque metal sheet. 4. Compact design of the drive unit. We proposed changing from the valve currently in use to the NBS-made uniflow valve. The uniflow valve operates without issues even under very high-frequency opening and closing conditions, and it is finished with a machining precision that makes it difficult for dust and other particles in the fluid to enter the gap between the body and the shaft. Additionally, a dust seal structure has been implemented at two locations on the valve body to prevent dust and tar from entering. To ensure optimal valve function under high-temperature operating conditions, the design was calculated based on thermal expansion rates, eliminating shaft binding and internal leaks due to temperature changes. Furthermore, since there were limitations on installation space for retrofitting to existing equipment, we requested the manufacturer to develop new seat materials. Initially, they responded that it was not feasible, but after repeated requests, they managed to produce test samples, which underwent opening and closing tests and leak tests before being commercialized. This allowed us to reduce the operating torque of the valve, resolving the issue with the adoption of a compact drive unit (air cylinder).
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