Chemically stable, high-strength, high-stiffness PEEK valve discs effectively extend component life

Chemically stable, high-strength, high-stiffness PEEK valve discs effectively extend component life

Valve plates are critical components of reciprocating compressors and directly affect their efficiency and reliability. When using steel with significantly shorter service life, if the valve plate ruptures, the steel fragments may cause serious damage to the cylinder, piston and piston ring. So the material it is made from is also very important, and with the addition of carbon fiber PEEK material, the use of durable PEEK sheets will avoid material loss behind the scenes and will provide significant added value to the end user in the oil and gas industry or fertilizer production plant by reducing downtime and associated costs.

The use of reciprocating compressors has become the backbone of most industries and PEEK flakes are not only an important part of any pneumatic or gas line, but also a key part of equipment or appliances in areas such as refrigeration.

Like most equipment, there is a constant quest to limit failures and downtime, and while compressor failures can seriously hamper the operation of industrial equipment, failures in consumer appliances can be very problematic as we don't usually want the compressor in a refrigerator or air conditioner to fail during the life of the product. In addition, compressor replacement is both expensive and time-consuming.

A durability analysis of the unit concluded that compressor valve plate failure is one of the main causes of failure. The compressor valve plate is located at the heart of the reciprocating unit and is responsible for carrying a large number of loads associated with the function of the compressor. In addition to this, it is in direct contact with the air, gas or fluid flowing through the compressor and is subject to corrosive forces as well as high pressures and temperatures.

PEEK valves7

PEEK Valve1

Reciprocating Compressor Application PEEK Valve Plate (PEEK Valve Plate)

Reciprocating compressor's have been used in a large number of industries. They are not only an important part of pneumatic or gas lines, but also a key part of equipment or appliances in areas such as refrigeration.

Like most equipment, manufacturers are constantly striving to reduce failure rates and downtime. Compressor failures can seriously hamper operations within an industrial facility, and we typically don't want the compressor in a refrigerator or air conditioner to fail during the life of the product. In addition, compressor replacement is both expensive and time consuming.

Durability analysis of this equipment has shown that compressor valve plate failure is one of the main causes of failure.

The compressor valve plate is located at the heart of the reciprocating arrangement and is responsible for carrying a large number of loads associated with the compressor's function. In addition to this, it is in direct contact with the air, gas or fluid flowing through the compressor and is subject to corrosive forces as well as high pressures and temperatures.

Materials used for compressor valve plates
Early valve plate materials used metal parts such as copper. While metals were inexpensive, could withstand sustained high impacts, and were not affected by pressure or temperature, corrosion would occur. With the development of new types of fluids, it became necessary to use materials that would not react in any way with the various chemicals that could pass through the compressor. Corrosion of metal compressor plates can also lead to splintering and breakage. While a broken plate can be replaced temporarily, metal shavings from the plate fall elsewhere in the unit and cause additional damage.

Metal valve plates are also ineffective at preventing the ingress of particulate matter. A piece of dirt or grit (often unavoidable in industrial applications) can become lodged in the equipment because the metal plate will not embed the particulate matter into the valve plate.

Polymers have been used as compressor valve plates since the 1960s. Early nylon valve plates offered the following advantages

Adequate impact strength

Resistance to chemicals and temperatures up to 120°C

Lightweight and inexpensive

Better lubrication

Easier management of debris that may fall into the equipment

Inhaled particles can become embedded in the material

However, nylon has significant moisture absorption and is not resistant to high temperatures. PEI and PAI were tested, but PEI did not provide sufficient abrasion resistance, PAI was more complex to mold, required a separate curing process, and the material had a high water absorption rate.

By the 1980's, PEEK appeared in a large number of applications and was tested in many applications, confirming that it was the ideal material for compressor valve plates. PEEK is now used in large quantities to ensure a certain degree of dimensional stability even after many years of operation.

Carbon fiber-modified PEEK can withstand temperatures of up to 300°C in the short term, well beyond the temperatures required for this application. It is also resistant to a wide range of chemicals and is only affected by concentrated nitric and sulfuric acids, which are highly unlikely to be present in a compressor.

PEEK's water absorption of 0.06% is also much lower than any of the polymers mentioned above.

The addition of fillers such as graphite or carbon fiber will further enhance the properties of PEEK.

Overall, the introduction of PEEK into this application has resulted in a dramatic increase in efficiency and durability, resulting in reduced maintenance costs and machine downtime.

PEEK Valve2

PEEK valves