Coal-fired power-plant desulfurization case study

Founded in November 2003, the plant brought three generating units into full operation by 2006. Unit 2 marked China’s total power-generation capacity surpassing 500 GW.
The plant adopted advanced desulfurization technology from Kawasaki Heavy Industries, achieving a 99.3% dust removal rate, over 95% desulfurization efficiency, and Zero Wastewater Discharge through wet desulfurization, high-efficiency dust control, and closed-loop coal storage solutions.

The Challenges of Wet Flue Gas Desulfurization (WFGD)
In WFGD systems, SO₂ from flue gas reacts with alkaline slurries such as limestone (CaCO₃), quicklime (CaO), or hydrated lime (Ca(OH)₂). The interaction between the high-velocity gas stream, solid desulfurizing agents, and the acidic slurry accelerates corrosion by damaging the protective oxide film on metal components, which increases wear on the valves. As the slurry contains abrasive particles, the combination of corrosion and erosion makes it difficult for conventional metal valves to withstand the harsh environment.

A Growing Problem: Unreliable Valves Leading to Production Losses
Since 2005, environmental regulations in China have enforced stricter SO₂ emission limits on Power Plants. However, the plant's initial use of imported metal valves frequently resulted in failures, leading to costly downtime. Each time the desulfurization system stopped for valve replacement, the environmental monitoring system would trigger alarms, exceeding monthly limits and prompting inspections from environmental authorities. In some cases, this could result in shutdowns lasting 15 to 30 days, causing severe operational losses.

Corroded metal valve surface

The Search for a Reliable Solution: Introducing KOWOV Ceramic Valves
In May 2008, the plant's desulfurization engineers explored alternatives, learning about KOWOV Ceramic Valves through industry magazines, valve distributors, and peer recommendations. After experiencing failures with both imported and domestic Ceramic Valves that used low-grade structural ceramics, the plant needed a high-performance, long-lasting solution.
Our technical team brought ceramic valve samples and ceramic grinding media for on-site demonstration. KOWOV ceramic valves feature:
● Elastic compensation structure to prevent clogging from solid particles.
● High-strength zirconia ceramic components that withstand both abrasion and corrosion.
The comprehensive demonstration of our ceramic materials, sealing performance, and success in other desulfurization systems gave the plant engineers confidence to place their first order.

KOWOV Ceramic Valve

Delivering Results: A Long-Term Partnership
● July 2008: The first DN100 KOWOV ceramic valve was installed for limestone slurry service.
● December 2008: The plant ordered four additional valves of the same specifications.
● January 2009: Four ceramic ball valves were installed for filtrate water and process water applications.
● By December 2013: Nearly 80 valves of various sizes (DN50 to DN150) were installed, improving system stability and efficiency.

Minimal Valve Replacement and Continued Success
From 2014 to 2021, the plant reported no need for additional valve purchases due to the exceptional durability of our KOWOV valves. In 2021, they reached out to us for spare parts and maintenance supplies, and we have since delivered 16 new units to support ongoing operations.
Over the past 15 years, nearly 100 KOWOV ceramic valves have been installed at the plant, with most operating for over 10 years without major issues. This success has solidified our KOWOV valves as essential components in their desulfurization system, and the plant remains one of our most valued long-term clients.

Innovating for a Sustainable Future
At Yantai Kingway Science & Technology Co., Ltd., we are proud to deliver reliable, high-performance ceramic valve solutions that ensure safe, efficient, and sustainable operations. We remain committed to tackling challenges in harsh working environments across various industries and contributing to the global pursuit of cleaner energy solutions.