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October 12, 2025

Development of wear-resistant throttle air volume control valve

**Abstract:** Based on the principles of porous jet diffusion and jet superposition, a dual-layer laminated structure was developed to create a wear-resistant throttle air volume control valve. This innovative valve can replace conventional throttling pipes and air volume control valves commonly used in dust removal systems to balance pipeline resistance. It offers superior wear resistance, an extended service life, flexible installation positions, and easy adjustment. The valve is particularly suitable for environments where high-speed airflow and abrasive particles are present, making it an ideal solution for industrial dust collection systems. **Keywords:** Air flow control valve; Throttle jet; Dust removal system; Throttle problems and analysis **1. Dust Removal System and Throttle Challenges** To maintain balanced resistance in dust removal pipelines and regulate airflow, throttle systems and air volume control valves are widely implemented. Typically, throttles are installed in short branch lines with relatively high resistance coefficients. The structure of a traditional throttle pipe is shown in Figure 1, where the opening rate is fixed and cannot be adjusted. Assuming the orifice has an opening ratio φ and the velocity inside the main pipe is v₀, the outlet velocity of the central core pipe can be calculated using formula (1), where φ = A / A₀ (A is the core pipe area, A₀ is the outer pipe area). With φ generally ranging from 0.2 to 0.5, the outlet velocity v becomes (2–5)v₀. For instance, when the pipeline speed is 16 m/s, the maximum outlet velocity can reach up to 80 m/s. If the throttle is placed too close to bends, tees, or other fittings (within 5–10 times the pipe diameter), this high-speed airflow can significantly increase wear on the downstream components. Since wear is proportional to the cube of the velocity [1], such conditions lead to rapid degradation of the throttle and surrounding piping. Field observations at the WISCO sintering plant showed that throttles near 6 mm elbows and tees were worn out within just one or two weeks. Despite its effectiveness in balancing resistance, the traditional throttle has limitations: fixed opening ratios and high-velocity airflow causing severe downstream wear. Similarly, conventional air volume control valves, such as flap and butterfly types, are prone to wear due to their design, which creates uneven airflow and sharp flow field changes. In metallurgical plants, newly installed valves often fail within days, leading to significant economic losses. Current solutions involve using thick steel or expensive wear-resistant materials, which are costly and do not address the root cause of wear. This paper introduces a new wear-resistant throttle air volume control valve that combines the functions of a throttle and an air control valve, offering improved performance and durability. **2. Structure and Working Principle of the Wear-Resistant Throttle Air Volume Control Valve** The structure of the wear-resistant throttle air volume control valve is shown in Figure 3. It consists of a valve body, a movable porous plate, a fixed porous plate, and an opening adjustment mechanism. Both plates have matching openings, which can be either slot-shaped or circular, as illustrated in Figure 4. The adjustment mechanism is isolated from the dusty airflow and uses a dual gear and rack drive system, preventing clogging and corrosion. By turning the adjustment knob, the movable porous plate moves left or right, allowing precise control of the airflow. When the openings of both plates fully overlap, the valve achieves maximum flow. When they are completely misaligned, the flow is minimized. An indicator on the adjustment device allows quick and accurate reading of the current opening ratio. The valve operates based on the principle of small-hole jet diffusion and superposition. As the airflow passes through the fixed and movable porous plates, parallel jets mix within a confined space. As shown in Figure 5, when two jets are close, their development affects each other. After merging, the jets form a uniform jet that mixes quickly over a short distance. This ensures even velocity distribution across the valve cross-section. The jet diffusion angle θ typically ranges from 2° to 16°, and the mixing point occurs at a distance x = b / tanθ, where b = 15 mm and θ = 12°, resulting in x ≈ 71 mm. This means that the airflow is evenly mixed within less than 100 mm, reducing the risk of high-speed erosion on the valve and downstream piping. Additionally, the porous structure minimizes vortex formation at the junctions, further reducing wear. By optimizing the collision angle between dust particles and the perforated plates, the valve avoids areas of high wear, where the incident angle is most damaging (20°–30°) [3]. **3. Conclusion** The wear-resistant throttle air volume control valve offers a reliable and cost-effective alternative to traditional throttles and air volume control valves. Its simple design, long service life, and ability to operate in any position make it highly suitable for industrial dust removal systems. Compared to conventional valves, it provides several advantages: (1) Simple and low-cost structure. (2) Excellent wear resistance, with a service life extended by 3–5 times. (3) Flexible installation without adverse effects on downstream fittings. (4) Dual gear and rack drive system, resistant to rust. (5) Easy operation and accurate adjustment of airflow. With its successful development, this valve has the potential to bring significant economic and environmental benefits, making it a promising solution for modern dust collection systems. **References** [1] Yao Qun et al. Dust pipe wear and anti-abrasion measures. Building Thermal Ventilation and Air Conditioning, 2000, 1. [2] Tan Tianyou, Liang Fengzhen. Industrial Ventilation and Dust Removal Technology. Beijing: China Building Industry Press, 1988, p. 130. [3] Chen Wansheng et al. Airflow balance debugging of WISCO four-burning dust removal system. Industrial Safety and Environmental Protection, 2001, 8.

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