Corrosion of metal valves and the use of synthetic material valves is a critical topic in the valve industry. Corrosion, generally defined as the degradation of metal materials due to chemical or electrochemical reactions with their environment, is a natural process that occurs when metals come into contact with various substances. To mitigate this damage, it's common to either isolate the metal from its surroundings or replace it with non-metallic synthetic materials.
Metal corrosion significantly affects the lifespan, reliability, and performance of valves. The combined effects of mechanical wear and chemical attack accelerate surface degradation, especially in environments where corrosive media such as oil, natural gas, and formation water are present. These media often contain harmful components like hydrogen sulfide and carbon dioxide, which can rapidly deteriorate metal surfaces and reduce the valve’s functionality.
The extent of corrosion depends on several factors, including temperature, mechanical stress, lubricant composition, exposure time, and the catalytic properties of the metal itself. As a result, both anti-corrosion treatments for metal valves and the application of synthetic materials have become key areas of research and development in the valve industry.
Anti-corrosion measures for metal valves typically involve applying protective coatings such as paints, pigments, or lubricants. These coatings help prevent corrosion during manufacturing, storage, transportation, and operation. The choice of method depends on the required protection duration, storage conditions, valve design, and economic considerations.
There are four main methods used to preserve metal valves: using volatile corrosion inhibitors in a sealed atmosphere, applying water- or alcohol-based solutions, coating the surface with anti-corrosion materials, and applying thin films or polymer coatings. Many manufacturers currently rely on lubricants and water-resistant compounds to protect their valves.
In contrast, synthetic valves offer significant advantages in aggressive environments. They are lightweight, corrosion-resistant, and their strength depends on the type and amount of reinforcing fibers used. Common fiber types include glass and graphite, with fiber content typically ranging from 30% to 40%. The chemical stability of these valves is determined by the resin used in the composite material. Thermosetting resins, such as polyester or epoxy, provide better heat resistance compared to thermoplastics like PVC or PPS.
Vinyl ester resins reinforced with glass or graphite fibers are among the most widely used synthetic materials in chemical process valves. While their tensile strength may be lower than that of metals, they can achieve comparable performance through thicker cross-sections and structural reinforcements like ribs.
Due to their excellent corrosion resistance, high strength, and light weight, synthetic valves have become a cost-effective alternative to traditional metal or fiberglass piping systems in corrosive applications. Their potential in chemical processing environments is vast and promising.
In addition to traditional materials, modern valve technology now incorporates ceramics, plastics, synthetic composites, and even shape-memory alloys. These advanced materials enable the creation of high-performance valves tailored for specific industrial needs. With ongoing technological advancements, the use of diverse engineering materials in valve manufacturing continues to expand, offering more efficient and durable solutions.
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