High Wear-resistant Butterfly Valve as New Type Butterfly Valve Release

It sets a new benchmark in the industry in terms of corrosion resistance. The new products introduced at this launch are designed to meet the growing demands of industries such as desalination, chemical processing, liquefied natural gas (LNG) and power generation, where valve failures pose significant operational safety risks and financial losses. ZZJG draws on the experience of global leading companies such as Kitz and Newco in Japan, and combines the innovation experience of other valve companies in China.

1. Beyond the tightness challenge:

The weakness of the traditional always the performance of the sealing. Especially under the high pressure，high temperature and corrosive medium. Leakage and evaporation are the main reason of the excessive wear and tear. The technical team of  the ZZJG by massive use in East middle and wild China chemical Industry,get lots of info of the site,developed a useful method.

Three-layer adhesive seal: ZZJG in simple

PTFE or EPDM lining outside (ZZJG is beside simple PTFE or EPDM lining), using a proprietary common molding process. The elastomer core (specially formulated nitrile, EPDM or FFKM, which is chemically resistant) provides the necessary compression recovery ability. The seat is molecularly bonded to an ultra-low-friction, wear-resistant PTFE/PEEK hybrid. Crucially, a third chemically resistant barrier layer, typically PFA or modified PTFE, is bonded to the valve body side, preventing the media from penetrating into the elastomer core. Failure to do so often leads to seal failure. In ZZJG The unique improvement results in a 40% increase in life expectancy in cyclic fatigue testing compared to standard designs. The laboratory verified its near-zero leakage according to ISO 15848-1 API 641 standards

Opening and closing of the sealing surface

Based on the successful use of the triple eccentricity technique, ZZJG engineers have made detailed improvements. The sealing surface between the tapered seat surface and the edge of the eccentric disc is simulated and optimized under pressure classes (PN10 to PN100/600). This minimizes contact stress during rotation while maximizing local stress at the closing point, ensuring metal-to-metal contact for true tightness even after thousands of cycles.

"Smart Seat" condition monitoring:

ZZJG integrates a separate microsensor within the seat ring to provide predictive maintenance. These sensors monitor parameters such as local temperature peaks, micro-deformations, and stresses. The data is transmitted wirelessly to the plant control system. Enables operators to proactively schedule maintenance before leaks occur, drastically reducing unplanned downtime.

Advanced Cryogenic Sealing Performance:

For critical hydrocarbons and LNG, ZZJG employs graphite-based fire-rated seals under normal operating conditions. At high temperatures, the seal degrades and the high-expansion graphite fills the voids, maintaining pressure integrity. The cryogenic model (-196°C) features a dedicated low-outgassing polymer to prevent leakage caused by seat contraction, and the solution has been perfected through repeated experiments with LNG terminal operators and test facilities.

2. Revolutionizing Corrosion Resistance: Materials Science Leads the Frontier

The rigors of modern industrial processes—highly acidic and alkaline chemicals, abrasive slurries, chloride-containing seawater, acidic gases—require the valve body and interior to withstand corrosion. ZZJG's materials strategic direction represents the direction of the industry:

Alloy Lining: ZZJG breaks through the limitations of traditional specialty alloys like Hastelly or Titanium alloys, pioneering the use of high-performance alloys in critical components. Specially developed FeCrNiMoCo-based alloys are applied to high-strength carbon steel or low-alloy steel bodies and discs in the form of dense alloy layers. These alloys exhibit superior resistance to pitting, crevice corrosion, and stress corrosion cracking in various corrosive media, outperforming traditional alloys like 316L alloy by 3-5 times in electrochemical testing. This method achieves better performance at a very low cost and weight, making it suitable for larger diameter valves (up to DN2800) commonly found in desalination outlets.

Nanostructured ceramic coatings to effectively prevent wear and erosion: For abrasive slurries involving abrasive slurries (e.g., mining, flue gas desulfurization systems) or high-speed fluids, ZZJG uses advanced high-speed flame spraying and suspension plasma spraying techniques to deposit ultra-hard and dense ceramic coatings in the valve cavity. Titanium dioxide nanocomposites and chromium nickel-chromium carbide coatings feature controlled porosity and nanoscale grain structures with a hardness of over 1200 HV. These coatings are applied to disc edges, seat contact surfaces, and stems. Material losses are significantly reduced. In the simulated limestone slurry cycle test, the loss is less than 0.1 mm after 1000 hours, resulting in an extended valve life.

Reinforced polymer composites for valve body linings: For highly corrosive chemical applications where the use of rare metal materials would be costly, ZZJG offers advanced polymer linings. In addition to standard PTFE, the company uses PFA (perfluoroalkoxy) and modified PTFE composites reinforced with carbon fiber or graphene nanosheets. These composites offer significantly improved resistance to denaturation, cold flow, and penetration barrier properties compared to standard PTFE. The lining is bonded using an advanced process that ensures zero voids even under harsh thermal shock tests (-50°C to 200°C cycles).

ZZJG's innovations don't stop on paper, the new butterfly valve series is already being used in critical infrastructures around the world:

Abu Dhabi National Oil Company (ADNOC) Zaqum Offshore Oilfield: DN600 300 lb metal seat triple eccentric butterfly valve with HEA-coated disc and body to handle acidic crude oil and high-pressure seawater injection, replacing older valves that have suffered stress cracking and erosion corrosion. Field reports show that after 18 months of continuous operation, zero maintenance was achieved, a record for such harsh environments.

Shawaba Phase IV desalination plant, Saudi Arabia: DN2400 resilient seat valves feature a triple adhesive seal and nano-ceramic coated discs to handle high-flow, abrasive seawater inhalation and brine discharge. Plant engineers reported a 70% reduction in seal replacement frequency compared to previous valves, which translates to millions of dollars in annual maintenance savings.

BASF Integrated Site in Ludwigshafen, Germany: DN400 lined valves handle concentrated hydrochloric acid flows with advanced PFA/carbon fiber composite lining and intelligent seat monitoring technology. Predictive maintenance successfully flags seat anomalies, allowing for regular intervention without interrupting the production process.

Yangjiang Nuclear Power Plant, China: DN800 fireproof cryogenic valves are encapsulated in graphite and cryogenic sealed for managing liquid nitrogen auxiliary systems, meeting stringent nuclear safety and leakage requirements.

"Butterfly valves are often thought of as a simple device, but achieving reliable long-term performance in today's most demanding applications requires deep materials science, precision engineering, and intelligent technology integration," said ZZJG's CTO. Our breakthroughs in sealing, especially the concept of molecular bonding, basically solve the problem of tight sealing. At the same time, our material strategy, especially alloy-clad layers and nanostructured ceramics, fundamentally changes the pattern of corrosion and erosion resistance. Not only do we keep pace with the world's leading companies, but we also set new benchmarks in the energy and water sectors, proven in rigorous field applications. ”

About Zhengzhou Jinggong Technology Co., Ltd. (ZZJG):

Headquartered in Gaoshan Town, Zhengzhou City, China, ZZJG is a high-tech enterprise specializing in industrial valve design, manufacturing, and global supply. ZZJG has a comprehensive portfolio of butterfly, plug, ball, gate, globe, check, control valves, and specialized blind/goggle valves to provide a full range of flow solutions for industries such as oil and gas, petrochemical, chemical, power generation, desalination, mining, and water and wastewater treatment. ZZJG holds a number of important international certifications (API 6D, API 607, API 600, ISO 15848, CE/PED, SIL), and has advanced manufacturing and testing facilities around the world.

For more information, please contact:

Email: [email protected]

Tel: +86-371-55659925

Mobile/WhatsApp: +86-18135671959

الموقع: www.zzjgvalve.com