Chlorine Dioxide Service Valves

Because Chlorine Dioxide is highly unstable and aggressive (often more corrosive than wet chlorine), Falcon utilizes specialized exotic alloys and severe-service designs to ensure safety and longevity.

For Chlorine Dioxide service, standard stainless steels (like 304/316) typically fail due to stress corrosion cracking. Falcon offers valves in high-grade exotic alloys specifically resistant to oxidizing environments:

• Primary Grades:Hastelloy C-276 (UNS N10276) and Titanium Grade 2 (Commercially Pure) or Grade 5.

   

   

• Alternative High-Performance Alloys: Hastelloy C-22, Super Duplex (UNS S32750/S32760), and PVDF-Lined or PFA-Lined carbon steel (for lower temperature/pressure applications).

• Trims: Often matched to the body material (e.g., Titanium trim in a Titanium body) to prevent galvanic corrosion.

Falcon offers a wide range of sizes to accommodate different piping scales, from dosing lines to main process headers:

• Standard Range:1/2" (DN15) to 24" (DN600).

   

   

• Specialty/Large Bore: Up to 48" (DN1200) for specific butterfly or gate valve configurations upon request.

• Pressure Ratings: Typically Class 150# to Class 900# (PN20 to PN150), with higher pressure classes available for specific injection systems.

Falcon provides several valve architectures optimized for hazardous chemical handling:

• Ball Valves: The most common choice for ClO₂. Available in Floating and Trunnion Mounted designs. They feature Full Bore flow to minimize pressure drop and cavity-free (or cavity-filled) seats to prevent ClO₂ gas accumulation inside the valve body.

• Plug Valves: Sleeved plug valves (often PTFE/PFA sleeved) offer a cavity-free design that is excellent for preventing the entrapment of unstable ClO₂.

• Butterfly Valves: High-Performance Triple Offset valves for larger diameter lines. These provide bubble-tight shutoff using metal-to-metal or laminated seals compatible with corrosive gases.

• Check Valves: Swing or Dual Plate check valves (with Hastelloy springs/internals) to prevent backflow into generation systems.

• Globe Valves: For precise flow throttling of precursor chemicals or ClO₂ solution.

Falcon employs rigorous standards to handle the toxicity and explosiveness of Chlorine Dioxide:

• Design Standards: Designed in accordance with ASME B16.34, API 6D, and API 600.

• Sealing Technology: Features Low Fugitive Emission packing (certified to ISO 15848-1 or API 622) to prevent toxic gas leakage into the atmosphere.

• Cleaning: Valves undergo "Oxygen Cleaning" or specialized Chlorine Cleaning processes to remove all oil, grease, and hydrocarbons which can react explosively with Chlorine Dioxide.

• Testing: Rigorous testing includes Hydrostatic Body Testing (1.5x design pressure), High-Pressure Pneumatic Seat Testing, and Helium Leak Testing to ensure zero leakage.

• Manufacturing: Investment casting (lost wax) for smaller sizes to ensure high surface finish and defect-free casting; Forged bodies for high-pressure small-bore valves to ensure structural integrity.