III. Feature Description

1. Wear – Resistant Design

• Hardened Components: The gate and other critical components in contact with the slurry are made of or coated with materials of high hardness. As mentioned earlier, a high – chromium alloy or a tungsten – carbide – coated surface on the gate can withstand the continuous scouring of abrasive particles in the slurry. In a copper – mining operation where the slurry contains a significant amount of hard – rock particles, the wear – resistant gate can maintain its integrity for a much longer time compared to standard – material gates, reducing the frequency of valve replacements.
• Self – Cleaning Mechanism: Some models of the TIANYU knife slurry valve are equipped with a self – cleaning feature. As the gate moves during opening and closing, it has a scraping or ejecting action that removes any accumulated solids from the valve seat and internal passages. This prevents the buildup of solids, which could otherwise cause leakage, increased wear, and reduced flow capacity. For example, in a coal – washing plant where the slurry contains fine coal particles and debris, the self – cleaning mechanism ensures that the valve remains free – flowing and leak – tight.

2. Zero – Leakage Sealing

• Advanced Sealing Technology: The valve uses a combination of elastomeric seals and precision – machined mating surfaces to achieve zero – leakage performance. The elastomeric seals are designed to deform slightly under pressure, conforming to the surface of the gate and seat to create a tight seal. Additionally, the sealing surfaces are machined to extremely high tolerances, minimizing any gaps that could allow slurry to leak. In a gold – mining operation where the slurry contains valuable minerals, zero – leakage sealing is crucial to prevent the loss of these minerals and to maintain environmental compliance.
• Sealing Compensation: A sealing compensation mechanism is often incorporated. This mechanism can adjust for any wear or changes in the sealing components over time, ensuring that the seal remains tight. For instance, as the elastomeric seal gradually wears due to the abrasive action of the slurry, the compensation mechanism can apply additional pressure or adjust the position of the seal to maintain the seal’s effectiveness.

3. High – Pressure Resistance

• Robust Structure: The valve body is designed with a thick – walled construction and a strong internal structure to withstand high – pressure conditions. The use of high – strength materials and advanced engineering techniques in the body design ensures that it can handle the internal pressure exerted by the slurry without deformation or failure. In a deep – sea mining operation where high – pressure pumps are used to transport the slurry from the seabed to the surface, the valve’s high – pressure – resistant structure is essential for reliable operation.
• Pressure – Balancing Features: Some models may incorporate pressure – balancing features to relieve internal pressure and reduce stress on the valve components. These features can include internal channels or chambers that equalize pressure across different parts of the valve, preventing excessive stress concentration and enhancing the valve’s long – term durability under high – pressure conditions.

4. Compact and Lightweight Design

• Space – Saving: Despite its robust performance capabilities, the valve is designed to be compact in size. This makes it easy to install in pipelines where space is limited, such as in underground mining galleries or in existing processing plants with congested piping systems. The compact design also reduces the overall footprint of the piping system, allowing for more efficient use of space.
• Lightweight Materials and Design: The use of lightweight yet strong materials, such as certain grades of stainless steel or composite materials in some components, helps to reduce the overall weight of the valve. This not only simplifies installation and maintenance but also reduces the load on the pipeline system, which can be beneficial in applications where the pipeline is suspended or has weight – bearing limitations.

IV. Manufacturing Process

1. Material Selection and Preparation

• High – Quality Raw Materials: TIANYU sources high – grade raw materials from reputable suppliers. Cast steel and stainless – steel ingots for the valve body are carefully selected based on their chemical composition and mechanical properties. For example, the carbon content in cast steel is precisely controlled to ensure the desired strength and toughness. The wear – resistant alloys for the gate are also chosen based on their ability to withstand the specific abrasion and corrosion conditions of the target mining slurries.
• Material Testing: Before manufacturing, all raw materials undergo rigorous testing. Chemical analysis is performed to verify the composition of the metals, and mechanical tests, such as tensile strength and hardness tests, are carried out to ensure that the materials meet the required specifications. Non – destructive testing methods, like ultrasonic testing and magnetic particle inspection, are used to detect any internal defects in the raw materials.

2. Casting and Machining

• Casting Process: For the valve body, precision casting techniques are employed. Investment casting or sand casting methods are used depending on the complexity and size of the valve. In investment casting, a wax pattern is created, coated with a ceramic shell, and then the wax is melted out. Molten metal is then poured into the ceramic shell to form the valve body. This process allows for high – precision casting, resulting in a smooth surface finish and accurate dimensions. Sand casting is used for larger – sized valve bodies, where a sand mold is created, and molten metal is poured into it.
• Machining Operations: After casting, the valve body and other components undergo extensive machining. CNC (Computer Numerical Control) machining centers are used to achieve high – precision machining. The sealing surfaces of the valve body and seat are machined to extremely tight tolerances, typically within a few microns. The gate is also machined to ensure a perfect fit with the seat and smooth movement during operation. Threads for connections and holes for mounting actuators are also precisely machined.

3. Assembly and Quality Control

• Assembly: The valve is assembled in a clean and controlled environment. Trained technicians carefully assemble the various components, ensuring proper alignment and connection. The sealing components are installed with great care to ensure a tight seal. The actuator, whether manual, pneumatic, or electric, is also installed and calibrated to ensure smooth operation.
• Quality Control Checks: Multiple quality control checks are carried out during and after assembly. Pressure testing is performed to ensure that the valve can withstand the rated pressure without leakage. A hydrostatic test is usually conducted, where the valve is filled with water and pressurized to a specified value (usually 1.5 times the rated pressure) for a certain period (e.g., 30 minutes). Leakage testing is also done using gas or liquid to detect any minute leaks. In addition, visual inspections are carried out to check for any surface defects, and functional tests are performed to ensure that the valve opens and closes smoothly and as designed.