3D-PRINTED VALVES
How much carbon can 3D-printed valve parts actually save ?
IMI and environmental consultancy Ricardo collaborate to find out which valve manufacturing process is most environmentally efficient .
By Bertrand Maillon , IMI
About the author
Bertrand Maillon uses his extensive experience in product development and manufacturing at IMI , where he leads the Retrofit3D team . Retrofit3D addresses complex customer challenges with custom-made valve trim solutions made using the latest additive manufacturing techniques . Bertrand champions digital production as a gamechanger for reducing carbon footprints and reimagining supply chains .
Additive manufacturing is often assumed to be more sustainable than subtractive production but there has been relatively little evidence to support that claim . Until now . In this article , Bertrand Maillon , Retrofit3D lead at IMI examines the findings from a landmark life cycle assessment completed with environmental consultancy Ricardo . Valves are inherently functional , which can make it easy to overlook their role in ‘ big picture ’ issues such as climate change . However , there ’ s good reason to make the connection and take it seriously . Heavy industry – such as refineries and chemicals – is facing growing pressure to decarbonise across the value chain , and research shows much of this pressure is now coming directly from customers . 1 Valves in good working order also have a major impact on plant performance . According to the European Sealing Association , the non-profit trade body representing manufacturers of sealing devices and materials , control valves account for roughly 60 % of a plant ’ s total emissions . In refineries , this value can increase to 70 %, though may only come from 1 % of a facility ’ s total installed assets . 2 These figures are enough for any facility to take action and is partly why far more attention is now being given to fugitive emissions . However , scrutiny cannot end here ; there are other ‘ hidden ’ issues that have a major impact on the sustainability of heavy industry .
Valve replacements
Every site , regardless of what is being produced , will need to regularly maintain , upgrade or change its control valves at some point . This regularity comes with a carbon penalty . With advances to
1 https :// www . pwc . com / gx / en / issues / esg / decarbonising-value-chain . html
2
ESA European sealing assoc . Pub . No . 014 / 05 manufacturing techniques , however , there is now scope to drive down embodied carbon , to the point where considerable savings can be made by making relatively minor changes . It ’ s this situation that provided the rationale for a life cycle assessment conducted by Ricardo on behalf of IMI . While important intelligence for IMI , the findings also have wider implications for the valve industry and industrial businesses seeking to drive down emissions in line with major targets .
Why analyse valve maintenance in such detail ?
Valves can be damaged due to the deleterious phenomena commonly observed in industrial flow control applications . Cavitation is among the most common of these issues and occurs with improper fluid velocity control . Cavitation in a control valve is damaging , resulting in a potential loss of control and the frequent replacement of spare parts . It can create excessive noise , the erosion of metal parts and pressure transients that result in valve and / or piping vibration and potentially fatigue failure . When these issues occur , facilities must either repair and replace valve parts or the entire valve itself . Repairs typically involve engineers fitting a new disk stack , with full valve replacement only being needed if the valve ’ s body is damaged , or when a facility ’ s process conditions change . Comparable replacement of core internal components is no guarantee of long-term success . This is especially true if the maximum flow velocity is not initially managed within the valve , or if the original valve trim is no longer suitable for the current process requirements .
20 Valve World February 2025 www . valve-world . net