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Jul 05,2023
Public Notice of 2020 Higher Education Institutions’ Outstanding Scientific Research Achievement Award (Science and Technology) Projects
Public Notice of 2020 Higher Education Institutions’ Outstanding Scientific Research Achievement Award (Science and Technology) Projects
I. Project Name
Key Technologies and Industrialization of High-End Process Valves
II. Nominating Organization
Zhejiang University of Technology
III. Project Overview
Process valves are critical equipment in process industries such as petrochemicals, energy metallurgy, and power & mining. With the trend toward larger-scale and high-end development in these process industries, process valves frequently encounter harsh operating conditions—including high/low temperatures, high pressures, easy vaporization, solid particle content, and strong corrosivity—posing significant challenges to the independent R&D and application of high-end process valves. The key technological difficulties lie primarily in the following three areas: First, there is a lack of comprehensive consideration of the multiphase and multiphysical coupling flow characteristics induced by the severe operating conditions of high-end process valves; consequently, no numerical computational method has been developed for the full-flow field under such multiphase and multiphysical coupling mechanisms, making it impossible to accurately predict the internal flow characteristics and performance of these valves. Second, there has been insufficient research on the fluid dynamics characteristics and material strain analysis of process valves under extreme conditions, resulting in a dearth of structural design guidelines for high-end process valves and preventing the establishment of advanced structural design technologies tailored specifically for harsh operating environments. Third, there is no established integrated manufacturing and forming technology for high-end process valves under severe conditions, which makes it difficult to ensure superior performance under actual harsh operating conditions. Currently, these critical bottleneck technologies remain unresolved, leaving China heavily reliant on foreign imports for high-end process valves used in its process industries—a situation that severely hinders the independent construction of process industry facilities and the progress toward becoming a modern industrial powerhouse. The project’s main innovative achievements are as follows: (1) A numerical computational model and algorithm were proposed for multiphase flows under severe operating conditions, accounting for weakly compressible gas-phase flow, liquid-phase cavitation, and particle collisions. This addresses the issue of low accuracy in numerical simulations of flow characteristics under the multiphase and multi-field coupling mechanisms within process valves, thereby enabling precise prediction of process valve performance under severe operating conditions. (2) A flow-structure design methodology was proposed, based on flow-field stability control, cavitation suppression, corrosion rate mitigation, and particle trajectory control. An integrated sealing structure—comprising rigid pressurization, spring preloading, and packing compensation—was established. This approach addresses structural failure issues arising from material strain under fluid loading, thereby ensuring the operational reliability of high-end process valves. (3) We have developed a high-end process valve manufacturing and forming technology that integrates intermittent machining, all-welded construction, and surface treatment. This technology addresses the challenges of customized manufacturing processes for process valves operating under harsh conditions, ensuring the long-term reliability and stable operation of high-end process valves. As a result, we have achieved industrialization and widespread application of high-end process valves, including ultra-high-temperature, extra-large-diameter butterfly valves, high-pressure, all-welded ball valves, ultra-low-temperature globe valves, wear-resistant double-disc gate valves, and corrosion-resistant rotary plug valves. The project’s products have been successfully applied by major national enterprises such as PetroChina, CNOOC, China Shenhua, and AVIC Engine Corporation, and have been exported to more than 20 countries and regions. Their key performance indicators outperform those of leading international brands in high-end process valves. Over the past three years, the project has generated cumulative additional sales exceeding 1.5 billion yuan and added profits of 150 million yuan. The project has been granted 26 invention patents and 2 software copyrights, published 12 SCI-indexed papers, released one monograph, and participated in the drafting and revision of 7 national and industry standards. This project has broken the foreign monopoly on China’s high-end process valve products, filled the gap in China’s independent R&D capabilities for high-end process valves, and provided critical equipment support for the independent construction and long-term development of China’s process industry facilities and energy strategic projects.
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IV. Information on Key Contributors
Ranking | Name | Administrative | Technology | Engaged in professional work | Work | Level 2 | Complete | Creative contributions to the major scientific and technological innovations of this project |
1 | Zhu Zuchao | National-Local Joint | Professor | Fluid Machinery and Engineering | Zhejiang University of Technology | Mechanical and Automatic Control | Zhejiang University of Technology | The project leader and coordinator is responsible for developing and implementing the project’s overall plan and technical roadmap. They have made significant contributions to Innovation Points 1, 2, and 3 by proposing a numerical computation model and algorithm for multiphase flow that takes into account weakly compressible gas-phase effects; establishing a design methodology for over-flow structures based on flow-field stability control; and pioneering advanced manufacturing and forming technologies for high-end process valves that integrate discontinuous machining, all-welded construction, and surface treatment. They are one of the chief editors of Monograph 1, a key contributor to Inventions 1–4, and an author of Papers 1 and 3. |
2 | Lin Zhe | None | Associate Professor | Fluid Machinery and Engineering | Zhejiang University of Technology | Mechanical and Automatic Control | Zhejiang University of Technology | I primarily completed the numerical computational method for multiphase flows that takes into account particle collisions, as described in Innovation Point 1. I developed a particle-wall collision model and proposed a numerical computational model for multiphase flows under the coupled effects of multiple phases and multiple fields, enabling accurate prediction of multiphase flows within process valves. I serve as the principal investigator for one of the supporting projects of this initiative: the “National Natural Science Foundation Project—Research on Transient Gas-Solid Two-Phase Flow Characteristics and Wear during the Opening and Closing Processes of Process Valves.” I am one of the chief editors of Monograph 1, a key contributor to Inventions 1–3, the corresponding author and first author of Paper 3, and one of the authors of Paper 1. |
3 | Liu Qi | None | Lecturer | Fluid Machinery and Engineering | Zhejiang University of Technology | Mechanical and Automatic Control | Zhejiang University of Technology | Primarily completed the numerical computation method for multiphase flow considering liquid-phase cavitation as described in Innovation Point 1, optimized the traditional cavitation numerical model, achieved accurate prediction of cavitation flow within process valves, and conducted cavitation experiments. Main contributor to Invention Patent 1. |
4 | Chen Desheng | None | Lecturer | Fluid Machinery and Engineering | Zhejiang University of Technology | Mechanical and Automatic Control | Zhejiang University of Technology | The primary task was to complete the flow-field stability-based control method for over-flow structure design, as described in Innovation Point 2. We optimized the internal flow stability control structure of process valves, thereby enhancing their operational reliability and stability. Additionally, we conducted experiments on internal flow-field stability control within process valves. |
5 | Zhang Guang | None | Lecturer | Fluid Machinery and Engineering | Zhejiang University of Technology | Mechanical and Automatic Control | Zhejiang University of Technology | Primarily, we will complete the flow structure design method based on particle trajectory control as described in Innovation Point 2. We will conduct visualization experiments on particle motion within process valves, establish the correlation between particle motion trajectories and wear on key valve surfaces, and propose a design methodology for preventing and controlling valve wear based on particle trajectory control. |
6 | Wang Ruohui | Board Secretary | Intermediate Engineer | Valve structural design | Wuzhou Valve Co., Ltd. | None | Wuzhou Valve Co., Ltd. | The primary tasks involved completing the seal structure design and the all-welded valve manufacturing technology as outlined in Innovation Points 2 and 3. Specifically, a seal structure design featuring rigid pressurization combined with spring pre-tightening was established, and an all-welded valve manufacturing process technology was proposed. This enabled the reliable design of high-pressure, fully welded valves. |
7 | Xia Chengrui | Chairman/General Manager | Senior Engineer | Corrosion-resistant valve design and development | Weiduli Valve Co., Ltd. | None | Weiduli Valve Co., Ltd. | Primarily completed the surface treatment technology for high-end process valves based on Innovation Point 3, proposing technologies for enhancing the adhesion of passivation oxide films on rare-metal alloy valve surfaces, ion modification, and anodizing treatments. These technologies have improved the high corrosion resistance and service life of process valves. I am a key contributor to Invention Patent No. 4. |
8 | Zhang Shougen | Deputy General Manager | Senior Engineer | Wear-resistant valve design and development | Zhejiang Gute Pneumatic Technology Co., Ltd. | None | Zhejiang Gute Pneumatic Technology Co., Ltd. | Primarily responsible for the design of wear-resistant structures under Innovation Points 2 and 3, as well as the industrialization and widespread application of valves. Proposed a height-difference structural design technique that effectively reduces wear on critical valve surfaces. Developed a series of wear-resistant valve products and successfully achieved their industrialization and widespread adoption. One of the primary inventors of Invention Patent No. 6. |
9 | Wang Chunchen | Chief Engineer | Senior Engineer | Valve structural design | Wuzhou Valve Co., Ltd. | Technical Department | Wuzhou Valve Co., Ltd. | Primarily, we will complete the flow field stabilization control method for process valves as outlined in Innovation Point 2, design various flow field stabilization structures for different valves, conduct visualization and pressure testing experiments on valve flow fields, identify the optimal structural configuration for valve flow passages, and develop process valve products that are stable and reliable in operation. |
10 | Chen Jie | Chief Engineer | Senior Engineer | Corrosion-resistant valve structural design | Weiduli Valve Co., Ltd. | Technical Department | Weiduli Valve Co., Ltd. | The primary focus was on the forming technology for manufacturing and processing high-end process valves as outlined in Innovation Point 3. The study analyzed the impact of various surface treatment technologies on the corrosion resistance of valves made from rare-metal alloys, and proposed advanced surface treatment processes for high-end process valves, which effectively enhanced both the corrosion resistance and service life of these valves. |
11 | Xiao Yabing | Deputy Director of the R&D Department | Senior Engineer | Wear-resistant valve structural design | Zhejiang Gute Pneumatic Technology Co., Ltd. | R&D Department | Zhejiang Gute Pneumatic Technology Co., Ltd. | Primarily, this work completes the structural design methodology for the flow passage components of process valves as outlined in Innovation Point 2. We conducted particle impact wear experiments to obtain insights into how various flow and structural parameters influence the distribution and extreme values of valve wear. This research reveals the underlying mechanisms of valve wear and proposes a wear prediction formula as well as a structural design approach for wear prevention and control. |
12 | Zheng Yifeng | Head of the Technology Department | Senior Engineer | Valve structural design | Wuzhou Valve Co., Ltd. | Technical Department | Wuzhou Valve Co., Ltd. | Primarily completed the forming technology for process valve manufacturing based on intermittent machining and all-welded construction, as described in Innovation Point 3. Proposed an intermittent machining technology and optimized the all-welded construction technology, enabling the comprehensive processing of high-end process valves and the development of a series of high-performance process valves. Main contributor to Invention Patent No. 5. |
13 | Xiao Han | None | Senior Engineer | Wear-resistant valve structural design | Zhejiang Gute Pneumatic Technology Co., Ltd. | R&D Department | Zhejiang Gute Pneumatic Technology Co., Ltd. | Primarily responsible for the development of a series of wear-resistant valve products under Innovation Point 3, conducting research on the effects of different structural and flow parameters on valve wear, and identifying the optimal structure for wear-resistant valves. This has effectively extended the service life of the valves and led to the development of a complete series of wear-resistant valve products. One of the primary inventors of Invention Patent No. 6. |
14 | Cui Baoling | None | Professor | Fluid Machinery and Engineering | Zhejiang University of Technology | Mechanical and Automatic Control | Zhejiang University of Technology | Primarily responsible for the numerical simulation of internal flow in process valves under innovation point 1. Based on a multiphase flow numerical model that accounts for weakly compressible gas-phase flow, liquid-phase cavitation, and particle collisions under severe operating conditions, we conducted numerical simulations of internal flow within process valves under various operating conditions, thereby establishing the correlation between operational parameters and internal flow characteristics. I am the primary contributor to Invention Patents 1, 3, and 4, the first author of Paper 1, and one of the authors of Paper 3. |
15 | Kim Ho-cheol | None | Associate Professor | Fluid Machinery and Engineering | Zhejiang University of Technology | Mechanical and Automatic Control | Zhejiang University of Technology | Primarily conducted research on the wear mechanism of process valves as outlined in Innovation Point 2. Performed numerical simulations and experimental studies on the distribution and extreme values of corrosion within process valves, elucidated the corrosion mechanisms of these valves, and proposed a predictive model for corrosion in process valves. First author of Paper 2. |
16 | Wang Xuefeng | Technical Department Manager | Engineer | Corrosion-resistant valve structural design | Weiduli Valve Co., Ltd. | Technical Department | Weiduli Valve Co., Ltd. | Primarily responsible for the structural design of the wear prevention system for process valves as outlined in Innovation Point 2. Based on a valve corrosion prediction model, numerical simulation analysis is conducted to evaluate internal corrosion in process valves. Combined with experimental studies, the effects of valve structure and medium parameters on corrosion are determined, enabling the identification of the optimal structural design for preventing corrosion in process valves. Furthermore, a series of corrosion-resistant process valves has been developed. |
17 | Chen Jinfa | Chairman | Senior Engineer | Valve structural design | Wuzhou Valve Co., Ltd. | None | Wuzhou Valve Co., Ltd. | Primarily responsible for the development of manufacturing and forming technologies for process valve components, as outlined in Innovation Point 3. Conduct an in-depth analysis of the structural design of the entire series of process valves, and develop targeted intermittent machining processes, all-welded processes, and surface treatment processes. This will result in a comprehensive manufacturing and forming technology for high-end process valves, and enable the development of a full range of high-end process valve products. |
18 | Xia Chongmao | None | Engineer | Corrosion-resistant valve product development | Weiduli Valve Co., Ltd. | R&D Department | Weiduli Valve Co., Ltd. | The primary task is to complete the structural design methodology for the flow passage components of process valves, based on mitigating corrosion rates, as described in Innovation Point 2. The study investigates the distribution of the flow field of highly corrosive media within the valve, establishes the correlation between structural parameters and shear stress in the flow field, and proposes a corrosion prevention structural design approach aimed at reducing shear stress in the flow field. |
19 | Li Laicong | None | Engineer | Wear-resistant valve product development | Zhejiang Gute Pneumatic Technology Co., Ltd. | R&D Department | Zhejiang Gute Pneumatic Technology Co., Ltd. | Primarily completed the overall sealing design for mid-to-high-end process valves as outlined in Innovation Point 2. Addressing the leakage issues caused by prolonged use of process valves, we developed and designed an integral sealing structure, establishing a comprehensive sealing design technology that integrates rigid pressurization, spring pre-tightening, and packing compensation. |
20 | Wu Zhiqiang | None | Engineer | Valve structural design | Wuzhou Valve Co., Ltd. | R&D Department | Wuzhou Valve Co., Ltd. | The primary task was to complete the all-welded process technology for high-end process valves as outlined in Innovation Point 3. Focusing on large-caliber, high-pressure valves, we conducted an in-depth analysis of their structural design and developed a comprehensive all-welded processing technology for high-end process valves. |
V. Information on the Principal Implementing Units
Ranking | Unit Name | The extent to which this project provides support. |
1 | Zhejiang University of Technology | Zhejiang University of Technology served as the lead institution for this project and provided the necessary facilities, human resources, material resources, and financial support to ensure its successful completion. The university played a crucial role in delivering the project’s core content and made significant contributions to Innovation Points 1, 2, and 3. This project was financially supported by funds from the National Natural Science Foundation, the Zhejiang Provincial Key R&D Program, and the university’s own funding for discipline development. Through a “industry-academia-research-application” collaboration model, the project promptly promoted and applied technological innovations, achieving remarkable economic and social benefits. |
2 | Wuzhou Valve Co., Ltd. | As the primary completing unit of the project, we collaborated with Zhejiang University of Technology to carry out R&D work on this project. Our key contributions include: (1) Participating in the research on the overall structural design and manufacturing/forming processes for high-end process valves operating under harsh conditions; (2) Taking charge of the research on intermittent machining and all-welded fabrication technologies; (3) Jointly collaborating to develop and manufacture a series of high-pressure, high-temperature valves; and (4) Being responsible for promoting and applying the large-diameter, high-temperature, high-pressure valve series in enterprises across industries such as energy and aerospace. |
3 | Weiduli Valve Co., Ltd. | As the primary completing unit of the project, we collaborated with Zhejiang University of Technology to carry out R&D work on this project. Our key contributions include: (1) Participating in the research on the overall structural design and manufacturing/forming processes for high-end process valves operating under harsh conditions; (2) Taking charge of the research on corrosion and cavitation prevention structural designs as well as surface treatment technologies; (3) Jointly developing a series of corrosion- and cavitation-resistant process valves; (4) Overseeing the promotion and application of this series of corrosion- and cavitation-resistant valves in enterprises across industries such as chemical engineering and metallurgy. |
4 | Zhejiang Gute Pneumatic Technology Co., Ltd. | As the primary completing unit of the project, we collaborated with Zhejiang University of Technology to carry out R&D work on this project. Our key contributions include: (1) Participating in the research on the overall structural design and manufacturing/forming processes for high-end process valves operating under harsh conditions; (2) Taking charge of research on wear prediction, wear prevention structural design, and methods for designing the overall sealing structure of valves; (3) Jointly collaborating to develop and manufacture a series of solid-containing wear-resistant valves; (4) Being responsible for promoting and applying the series of solid-containing multiphase flow valves in enterprises such as power and metallurgy companies. |
VI. List of Major Intellectual Property Rights and Standard Specifications, etc.
( 1) Intellectual Property Catalog
Intellectual Property Category | Intellectual Property Name | Country (Region) | Authorization number | Authorization Date | Rights holder | Inventor | Valid status of the invention patent |
Invention patent | A new type of magnetically controlled regulating valve | China | ZL201610708494.8 | 2018.12.04 | Zhejiang University of Technology | Lin Zhe, Ma Chuanjing, Liu Qi, Zhu Zuchao | Valid patent |
Invention patent | A ball valve for coal-water slurry transportation | China | ZL201510922735.4 | 2018.01.12 | Zhejiang University of Technology | Lin Zhe, Zhang Yifan, Xu Benliang, Zhu Zuchao | Valid patent |
Invention patent | Flat gate valve for dilute-phase pneumatic conveying | China | ZL201510167711.2 | 2017.05.03 | Zhejiang University of Technology | Zhu Zuchao, Lin Zhe, Ma Guangfei, Cui Baoling, Xu Hongguang | Valid patent |
Invention patent | A multi-sealed and diverter-type pressure-reducing throttling shut-off valve | China | ZL201110077587.2 | 2012.07.11 | Zhejiang University of Technology | Cui Baoling, Song Zhiwei, Zhu Zuchao, Zhang Yuliang, Xia Chengrui | Valid patent |
Invention patent | A high-temperature, high-pressure hard-sealed ball valve | China | ZL201610429563.1 | 2018.01.12 | Wuzhou Valve Co., Ltd. | Hu Jiantian, Chen Xinghan, He Xiangping, Zheng Yifeng, Li Junhui, Chen Changben, Ye Kaiqiang, Jiang Yilong | Valid patent |
Invention patent | A wear-resistant gate valve structure | China | ZL201510685147.3 | 2017.11.24 | Zhejiang Gute Pneumatic Technology Co., Ltd. | Zhang Shougen, Ye Jianshan, Xiao Han, Zheng Rusheng | Valid patent |
( 2) List of Representative Papers and Monographs
Author | Paper/Book Title | Journal/Publication of Papers/Books | Volume, Issue, and Page Numbers | Publication time | Journal Category |
Zhu Zuchao, Lin Zhe | Process Valve Fluid Dynamics | Mechanical Industry Press | ISBN 978-111-62768-5 | 2019 | Monograph |
Baoling Cui 、 Zhe Lin 、 Zuchao Zhu 、 Huijie Wang 、 Guangfei Ma | Influence of the ball valve’s opening and closing process on external performance and internal flow characteristics | Experimental Thermal and Fluid Science | 80: 193-202 | 2017 | SCI |
Haozhe Jin 、 Zhijian Zheng 、 Guofu Ou 、 Lite Zhang 、 Jie Rao 、 Geping Shu 、 Chao Wang | Failure Analysis of a High-Pressure Differential Regulating Valve in Coal Liquefaction | Engineering Failure Analysis | 55: 115-130 | 2015 | SCI |
Zhe Lin 、 Huijie Wang 、 Zhaohui Shang 、 Baoling Cui 、 Chongxi Zhu 、 Zuchao Zhu | Effect of cone angle on the hydraulic Characteristics of a globe control valve | Chinese Journal of Mechanical Engineering | 28(3): 641-648 | 2015 | SCI |
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