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Valves are the indispensable force of every pharmaceutical and biological enterprise, especially the fermentation workshop and refining workshop. They are used to cut or communicate fluids such as steam, water, culture medium and air, regulate the flow of fluids, and control the pipeline or container. Control the pipe fittings that are indispensable for pressure. However, ordinary valves used in fermentation production will often see leakage (bleeding), resulting in common run, run, drip, and leak phenomenon of valves. Some even have serious infections and cans, which cause valve production enterprises to produce bacterial sources. Pollution and material waste, reduced production, delays in delivery, increased costs, etc. Using modern technology and advanced technology to research and develop new products that can fully meet the requirements of the fermentation industry, to meet the growing needs of the fermentation industry.
2. The new antibiotic multifunctional valve design is in accordance with the GMP standards of the pharmaceutical industry. The new antibiotic multifunctional valve not only has good sealing performance, but also has strict requirements on the sealing material. It can adapt to higher temperature and pressure from the material; the erosion, corrosion and wear of the valve sealing material are not affected by the medium during operation, which can ensure that the valve does not seep (bleed) during the service period. We focus on the internal structure design of the valve, so that each valve can effectively prevent the derivation and reproduction of harmful bacteria in the valve body, prevent the application of the company from bacteria and cans, and continuously improve the fermentation yield of the application unit and the enterprise. Economic benefits.
3. Main features of the valve structure (innovation point)
The new antibiotic multifunctional valve (hereinafter referred to as the new functional valve) mainly consists of valve body, exhaust valve, sealing ring, conical valve disc, lower valve flap, gasket, pressure plate, spring seat, spring, upper valve flap, diaphragm, Diaphragm, split ring, disc screw cap, valve stem, bonnet, stem nut, hand wheel, PTFE gasket, etc. However, the new function valve is quite different from the general valve-stop valve. The new function valve is operated by the original three valves, and is now converted into a three-in-one operation, which greatly changes the original appearance, which saves money and saves money. The original sealing valve has poor sealing performance, and the diaphragm has low temperature resistance. Many pharmaceutical companies rely on high-priced diaphragms to maintain their operations. The new functional valve is replaced by a three-in-one throttle valve, a shut-off valve and a diaphragm valve. It is also based on the anti-vibration valve. It has the following five characteristics:
(1) The valve body (No. 1) has a spiral shape in the flow path. There is no inflection point and no dead angle in the circulation process. There is a diaphragm on the upper side, no material is retained, and the material can be transported safely and hygienicly, which is easy to clean and therefore not easy to occur. It is contaminated with bacteria and has a vent hole at the bottom, which fully meets the requirements of the pharmaceutical industry GMP standards.
(2) The threaded part of the valve stem (No. 18), no matter how the valve is opened or closed, the threaded part of the valve stem will not directly contact any working medium in the valve, thus completely avoiding the material bonding at the stem thread. And the opportunity to stay, so the stem and material are isolated.
(3) The contact between the sealing ring and the tapered surface is double-closed by the cross-section contact. The contact surface is strengthened by laser cladding, which greatly improves the surface hardness and wear resistance and prolongs the service life of the valve.
(4) Valve body materials According to different working media, process (temperature, pressure) requirements of different enterprises, choose different corrosion-resistant materials, such as 304 and 316L.
(5) The valve has reasonable design, small volume, excellent material, no dead angle, good sealing performance, strong anti-corrosion performance, uniform operation, convenient operation, durable wear, convenient cleaning, thorough disinfection, energy reduction, time saving and convenient assembly. More than a dozen advantages such as spare parts.
4. The valve body design valve body is one of the important parts of the valve. It acts as a medium flow channel and controls the throat main road, and is subject to the pressure, temperature, erosion and corrosion of the working medium. The key to valve design is the valve body design. Although the structure of the valve body is ever-changing, various, and colorful, the functional division of the two sections is always the same. The longitudinal section of the valve body determines the flow direction of the fluid, and the cross-section of the valve body determines the fluid flow through the section. According to the principle of fluid mechanics, combined with the requirements of the GMP standard of the pharmaceutical industry, we designed the longitudinal section of the valve to have a tapered surface and a cross section, and the flow direction forms a spiral shape, allowing the material to quickly leave the valve. There is no inflection point and no dead angle on the whole process line, so that the flow direction and the shape of the channel do not stay and the fluid has no resistance. The contact surface of the sealing ring on the valve body is designed to be flared, so that the material is sprayed like a fountain. (No. 3), which is conducive to the flow of the working medium. A venting hole is added at the bottom of the valve body, which is beneficial to the discharge of sewage in the pipeline at the beginning of production, and is conducive to disinfection in the production process. For some companies that do not use this vent, we have also designed a venting valve body for these companies.
5. The laser-treated valve sealing surface of the sealing surface is subjected to various corrosion and erosion of the working medium at a high temperature and pressure for a long time, and some also suffers from the abrasion of the sealing surface between the sealing surfaces. The high-speed laser (HGL-90 5KW) focused laser is used to perform single-channel laser scanning on the sealing surface of the valve body and the valve flap (No. 3) (process parameters are: laser power W=3kw, scanning speed U= 8-20mm/s, spot size = φ5-φ10mm), controlling the energy density and scanning speed, the fusion layer and the substrate can be firmly combined, the mutual fusion zone is small, and the thermal stress of the valve body is small. The thickness of the Co-based or Ni-based alloy layer can be up to 3mm, and the surface of the coating is smooth and flat, which can increase the hardness by 20%-40%. Test and production applications show that the laser sealing surface of the valve sealing surface has good performances such as wear resistance, erosion cavitation, corrosion fatigue resistance and high temperature impact fatigue under severe working conditions, which improves the use of the valve. Reliability, safety and longevity.
6. The choice of sealing material and its performance are closely related to the quality of the valve. Some sealing materials are not suitable for this fluid condition, which is not conducive to sealing. Some sealing materials are suitable for this fluid condition and are beneficial for sealing. The valve products manufactured by our company have different structures and different specifications. The seals are made of different materials due to the requirements of the company's working conditions. We are equipped with heat resistance, wear resistance, alkali resistance, acid resistance, and four commonly used working conditions, which are listed in the table below. Serial number Working condition sealing material Temperature resistance Solvent resistance Acid resistance Alkali resistance 1 Aramid fiber better general better better 2 fluororubber excellent better excellent excellent 3 Phenolic fiber better better excellent excellent 4 carbon fiber excellent general better better 5 PTFE excellent excellent excellent excellent 6 EPDM better general excellent excellent
7. Looking forward to the future, the new antibiotic multi-function valve has achieved the expected results in the pre-development period in the fermentation industry. It is a very gratifying thing. In the future, the pharmaceutical company will use the valve to have a good effect. The valve can completely replace the existing antibiotic valve in China. And diaphragm valve, because it has a unique trick, how to buy three things at the same price? The valve design and quality are in full compliance with the requirements of the pharmaceutical industry GMP standard (Q/WJF01-2002). This research has applied for new national utility patents, appearance patents and invention patents, so this research is only a long march. There are still many things to be done in the fermentation industry. When summing up the experience of industrial fermentation at the National Pharmaceutical Conference over the years, it was pointed out: "In most industrial fermentations, microbial contamination is a major concern, such as the ability to use many bioengineering technologies. When the medium and equipment are sterilized, the probability of fermenting the bacteria can be reduced by 10%-20%. The revitalization of the national industry and the development of the valve industry depend on technological innovation. Our company is determined to increase capital investment, strengthen information communication, strengthen new product development, and develop second-generation and third-generation anti-bacterial multi-function valves with high-tech and advanced technology. Our company insists on using information technology to promote industrialization, industrialization to promote informationization, and a new industrialization path with high technology content, good economic returns, low resource consumption, less environmental pollution, and full utilization of human resources advantages. The valve industry is a promising industry. The fermentation industry is the main battlefield for our struggle. We must do our utmost to continue to work hard for the growing and prosperous pharmaceutical and bio-fermentation industries.
Description of new antibiotic multifunctional valve application technology
1. The origin of the problem is that the fermentation industry is an ancient traditional industry in China. It has been famous all over the world for its excellent production of Maotai and Wuliangye technology. With the development of the times, the advancement of science and technology, and the continuous improvement of people's living standards, the application fields of fermentation technology have been continuously expanded and extended. Now in the process of pharmaceutical antibiotic raw materials, bio-chemicals, biological pesticides, enzyme preparations and food fermentation production, It has also gained a new world of development. Along with this, the large-volume, modernized and automated industrial production of pharmaceutical drugs has increasingly exposed that China's production equipment and fermentation production processes are far from meeting the requirements of the fermentation process. If these problems are not resolved in time, they will surely Seriously restricting the further healthy development of the industry.