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Energy-saving control valve: A Path Toward Lower Energy Consumption
Employing control valves with a low pressure-drop ratio helps reduce the proportion of the valve's pressure drop relative to the system’s total pressure loss, thereby lowering energy consumption. As a result, designing control valves with a low pressure-drop ratio has become one of the key development directions—while another promising avenue is the adoption of low-impedance control valves, such as butterfly valves or eccentric rotary valves. Additionally, self-operated control valves are gaining traction; for instance, directly utilizing the downstream medium’s pressure to create a self-regulating control system, leveraging the controlled medium’s own energy to maintain precise pressure regulation downstream.
Release date:
2022-01-10
Energy conservation, which reduces energy consumption and enhances energy efficiency, is a key development direction for control valves. The main areas of advancement include the following:
1. Employing control valves with a low pressure-drop ratio helps reduce the proportion of pressure drop contributed by the valve across the entire system, thereby lowering energy consumption. As a result, designing control valves with a low pressure-drop ratio is one of the key development directions—another promising avenue is the adoption of low-impedance control valves, such as butterfly valves or eccentric rotary valves.
2. Utilize self-operated control valves: For instance, directly use the pressure of the medium downstream of the valve to form a self-operated control system, leveraging the energy from the controlled medium itself to regulate the downstream pressure.
3. Regulating valves equipped with electric actuators. Pneumatic actuators require consistent air pressure throughout the operation of the regulating valve. While energy-efficient amplifiers can be used to minimize air consumption, over time, the overall air usage remains substantial. In contrast, electric actuators only need power when adjusting the valve opening—and once the desired position is reached, no further power is required. From an energy-saving perspective, electric actuators therefore offer clear advantages over pneumatic actuators in terms of efficiency and reduced energy consumption.
4. Utilizing a piezoelectric control valve. In intelligent electric valve positioners, the piezoelectric valve consumes air supply only when the output signal increases.
5. Utilizing a valve core with a balanced design reduces the actuator thrust or torque, minimizes the size of the diaphragm chamber, and lowers energy requirements.
6. Replace control valves with variable-frequency drive (VFD) technology. In applications involving high pressure drops where energy consumption is significant, VFD technology can be employed to adjust the speed of relevant operating equipment, thereby reducing energy usage.
Protecting the environment has become essential—environmental pollution has already turned into a public nuisance. Among the sources of environmental contamination caused by control valves, noise and leakage stand out as particularly significant concerns. In particular, the noise generated by control valves poses an especially severe threat to the environment.
1. Reducing control valve noise: Develop various methods to minimize control valve noise, ranging from optimizing the valve flow path and internal components to analyzing noise sources and implementing targeted noise-reduction measures. Key approaches include designing noise-reducing control valves and specialized valve internals, as well as strategically distributing pressure drops and employing external noise-control techniques—such as adding isolation devices or installing silencers.
2. Reducing atmospheric pollution from control valves. Atmospheric pollution caused by control valves refers to issues like "running," "venting," "dripping," and "leaking." These leaks not only result in the wastage of materials or products but also contaminate the atmosphere, sometimes even leading to accidents such as injuries, fatalities, or equipment explosions. Therefore, developing advanced valve packing designs and materials, as well as improving valve sealing technologies, will become a critical area of research for control valves in the future.
The advancement of cutting-edge scientific technologies—such as computer science, control theory, and automation instrumentation—has significantly propelled the development of control valves. For instance, innovations like fieldbus-based control valves and intelligent valve positioners have emerged, alongside the integration of digital communication into valve systems. In turn, advancements in control valves are spurring progress in other scientific fields, including research into corrosion-resistant materials, methods to mitigate and reduce noise, and studies on fluid dynamics. As fieldbus technology continues to evolve, control valves are becoming increasingly open, smarter, and more reliable. Together with other industrial automation instruments and computer-controlled systems, these advancements will further enhance the functionality of industrial process control, enabling greater precision, improved performance, and more effective outcomes. Ultimately, this evolution will play an even more critical role in supporting China’s modernization efforts.
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