Summary
One major petrochemical producer improved their Butadiene reactor uptime by eliminating frequent isolation valve failures in a challenging Magnesium Oxide and Silica catalyst application.
Challenge
One major petrochemical producer had been working to improve the productivity of their 1,3 Butadiene production process which required the addition of Magnesium Oxide and Silica catalysts in the form of powder. A variety of ball valves had all failed in this application as the fine powder infiltrated the valve cavity to enter behind the floating seat and seize the valve. This was forcing a shutdown of the reactor every 6-8 weeks that had been straining productivity and elevating maintenance costs for years.
Solution
Emerson’s engineering team collaborated with the customer to propose a breakthrough technology now available through a recent acquisition. The new AEV™ 2XC™ Severe Service C-Ball Valve features a revolutionary design in which a “C” shaped ball closes via cam effect against a single fixed seat, thereby eliminating any cavity behind the seat.
This design immediately solved the problem because without a cavity, there is absolutely no opportunity for powder to infiltrate behind the seat and cause the valve to seize. The valve also achieves longer life with a double eccentric design providing tight shutoff while eliminating rubbing of the ball and seat during rotation to minimize wear.
Result
The AEV 2XC Severe Service C-Ball Valve solved the recurring failure of traditional ball valves to eliminate the frequent reactor shutdowns and improve productivity. Additionally, the frequent labor and equipment maintenance costs associated with changing out the seized valves were eliminated. It was also no longer necessary to maintain a costly inventory of replacement valves and spare parts. Overall, the adoption of Emerson’s AEV C-Ball Valve technology has reduced the plant’s valve asset investment while improving unit performance and profitability.
