Overview: Solving Corrosion & Leakage Issues in a Chemical Processing Plant
In the chemical industry, where pipelines carry highly corrosive and hazardous fluids, valve performance is critical. A leading chemical manufacturer in the South Africa was struggling with frequent valve failures in their acid-handling unit, leading to safety risks, downtime and high maintenance costs.
After evaluating their pipeline system, we provided a corrosion-resistant valve solution that not only solved their leakage issues but also improved operational efficiency. Here’s how we helped them achieve long-term reliability.
The Challenge: Frequent Corrosion & Safety Concerns
The plant was using standard stainless steel valves for controlling the flow of sulphuric acid and other corrosive chemicals. However, they were facing serious challenges:
🔹 Valve body corrosion, leading to leaks
🔹 Frequent maintenance shutdowns, affecting production
🔹 Gasket failures causing hazardous chemical exposure risks
🔹 Increased operational costs due to premature valve replacements
With chemical exposure degrading their existing valves, they needed a high-performance solution that could withstand aggressive media while ensuring safety and efficiency.
Our Solution: Upgrading to PTFE-Lined Butterfly Valves
After analyzing their process conditions—fluid composition, temperature, pressure, and flow rate—we recommended switching to PTFE-lined butterfly Valves.
Why PTFE-Lined Butterfly Valves?
🔹 Superior Corrosion Resistance – PTFE lining prevents chemical attack, extending valve life.
🔹 Zero Leakage Design – Eliminates hazardous leaks, ensuring worker and environmental safety.
🔹 Lightweight & Compact – Easier to install and operate compared to traditional metal valves.
🔹 Cost-Effective Solution – Reduces maintenance frequency, cutting down long-term costs.
Our team worked closely with the plant engineers to select the right valve sizes, materials, and pressure ratings to ensure a perfect fit for their system.
The Installation: Precision & Quality Assurance
The installation process was executed with high precision to ensure maximum efficiency. Key steps included:
🔹 Thorough pipeline flushing – Removing chemical residues before installation.
🔹 Proper gasket selection – Using PTFE gaskets to complement the lined valves.
🔹 Bolt torque management – Preventing overtightening, which can damage the PTFE lining.
🔹 Pressure & leak testing – Ensuring 100% leak-proof performance before system startup.
The Results: Improved Safety & Zero Maintenance Downtime
Within six months of installation, the plant saw a major improvement in performance:
🔹100% elimination of leakage incidents
🔹 Valve lifespan extended by 3X compared to previous valves
🔹Zero emergency maintenance shutdowns
🔹Reduced operational costs by 35%
The plant manager was highly satisfied with the results, highlighting how choosing the right valve completely transformed their operations.
The Right Valve = Long-Term Success
The corrosion-resistant valve selection is key in chemical processing plants. By using the correct PTFE-lined butterfly valves, the company not only enhanced safety but also boosted efficiency while significantly cutting maintenance costs.
At C-Way Engineering Exports, we specialize in providing industry-specific valve solutions that ensure maximum reliability and safety for chemical industries worldwide.
Need high-performance valves for chemical processing? Contact us today for expert recommendations and customized solutions!
Client Review from South Africa Chemical Plant
“High-Quality Valves & Exceptional Service!”
“At our chemical processing facility in South Africa, we struggled with frequent valve corrosion and leakage issues, leading to costly downtime. After switching to C-Way Engineering Exports’ PTFE-lined butterfly valves, our operations improved significantly. These valves offer excellent corrosion resistance and reliable performance, even under harsh conditions. Their team provided expert advice, timely delivery, and a seamless installation process. It’s been over a year, and the valves are still performing perfectly. We highly recommend C-Way Engineering Exports for their top-quality industrial valves and outstanding service!”
— Johan M., Maintenance Supervisor, Durban, South Africa
