Arun Prasath, Principal Consultant, Industrial Technologies, Frost & Sullivan

Valves are essential components of pipelines and numerous processes in a variety of industries, as they are used to regulate the flow of liquids, gases, or any form of fluidised solid. Industrial valves play a key role in various process industries, including oil and gas, chemicals, power generation, water treatment, food & beverage, mining, pulp & paper, pharmaceuticals, etc. The future of industrial valve design and manufacturing has immense potential for sustainability, efficiency, and innovation because of the increasing automation in complex industries and technological advancements. Valve manufacturers are focusing on industry advancements and reducing fabrication costs to meet industry-specific requirements, as innovative valves are increasingly popular in various sectors like oil & gas, chemicals, and power generation. The latest valve technology innovations are set to redefine industry standards, providing superior control, durability, and safety.

This article delves into emerging global trends in valve designs and manufacturing as well as the advancements in automated valve usage in various industrial sectors.

Emerging global trends in valve manufacturing

Valve technology is advancing at a rapid pace to meet the growing demand for precision, efficiency, and safety in a variety of sectors, including oil and gas, chemical, and pharmaceuticals. The industry is prioritising the enhancement of valve reliability and durability in response to the increasing pressure, temperature, and operational conditions. Environmental considerations are also crucial, with regulations requiring valve manufacturers to reduce emissions, and energy consumption, and ensure leak-proof operations.

The rise of automation has pushed advancements in valve technology. Intelligent valve systems, along with advanced sensors and automated control mechanisms, are becoming the norm, allowing businesses to retain operational precision, eliminate human mistakes, and boost overall productivity. In addition to this, The Industrial Internet of Things (IIoT) enables predictive maintenance for valves, lowering downtime and maintenance costs.

Trends in industrial valves design

Recent advancements in stainless steel control valves, globe valves, pressure safety valves and cryogenic valves design:

• Stainless steel control valves are preferred for industries with high corrosion resistance, like chemical processing and water treatment. Recent design improvements improve flow control precision, ensure longer life spans, and resist aggressive chemicals. Multi-functional features enhance control and performance in challenging environments, making Stainless steel control valves a preferred choice.
• Recent advancements in cryogenic valves have improved efficiency and sealing capabilities, enabling safer and more efficient operations in industries like transportation and storage of liquefied gases, especially at lower temperatures.
• Innovations in safety valve design aim to improve response times and reliability under extreme conditions, especially in industries like oil refining and power generation. Modern safety valves are made with superior materials, accurate pressure-release mechanisms, and fail-safe features to prevent catastrophic system failures.
• Valve manufacturers are focusing on optimising valve design using CFD and FEA simulation tools, resulting in high-performance globe valves with features like non-rotating stem globe design, in-suite seat arrangement, seal-welding of threaded seat ring, and guided disc arrangement.

Emerging technologies in valve design

Application of Digital Twins in Valve Design: The digital twin allows check valve suppliers to continuously improve their designs, eliminate costly prototypes, and expedite product delivery. This technology allows for virtual reality design changes, reducing physical testing time and resulting in shorter production times and improved product quality.

Implementation of Additive Manufacturing: Additive manufacturing, including 3D printing, has significantly improved valve design and performance, making complex designs easier and more accurate. 3D printing allows valve manufacturers to produce intricate, small parts with higher precision and flexible valve designs. It helps companies explore new designs, produce prototypes quickly, test them, and revise them as needed, accelerating the development cycle.

Increased usage of Simulation Software: Simulation software is increasingly being utilised in valve manufacturing due to the increasing demand for non-standard, customised products across various industries. This trend can reduce fabrication costs and development time by allowing valve manufacturers to analyse and test various solutions without the need for multiple designs and prototypes.

Trends in Industrial Valve Automation: Automation in valve systems is improving industrial operations' accuracy and productivity by reducing human intervention. Modern sensor technologies are integrating automated control valves to maintain optimal flow rates, pressure, and temperature, reducing downtime and boosting operational performance.

Automatic valves, including electric, hydraulic, pneumatic, solenoid, and digital mechanisms, are gaining popularity in manufacturing plants for unmanned operations with precise flow modulation. They offer advanced preventive maintenance, eliminating the risk of frequent shutdowns. Leading valve manufacturers prioritise safety and dependability in valve-centric sectors, focusing on fail-safe systems, real-time monitoring, and improved diagnostics in future production.

The global expansion of industrial infrastructure presents a significant opportunity for valve manufacturers to enhance efficiency and safety through the adoption of smart technologies. Intelligent valve development is a significant digitalisation advancement in the valve industry. Industrial automation, data analytics, and connectivity are driving the development of smart valves, enabling real-time monitoring, predictive maintenance, and remote control.

Valve manufacturers worldwide are utilising AI to enhance product performance, reliability, and process efficiency in their respective industries. AI and ML are expected to improve valve manufacturing efficiency, reliability, and performance, with applications including predictive maintenance, fault detection, and optimised valve selection in the valve industry.

Conclusion

The integration of digital transformation, advanced materials, additive manufacturing, automation, and smart technologies is driving significant advancements in industrial valve manufacturing. Emerging trends in cryogenic, safety, and stainless-steel control valves reflect the industry's commitment to innovation, enhancing safety, efficiency, and global competitiveness. As the industry evolves, these specialised solutions will play a crucial role in shaping the next wave of industrial progress.

Arun Prasath – Principal Consultant, Industrial Technologies, Frost & Sullivan.

With 16 years of experience in product marketing, market research, and consulting, Arun Prasath has led 70+ market research and consulting engagements across global markets. His expertise includes market opportunity assessment, competitive analysis, M&A due diligence, and go-to-market strategies, with a strong focus on industrial automation, process control, and motion control. He has worked closely with industry leaders like Emerson, Siemens, ABB, and Flowserve, contributing to strategic consulting and thought leadership.

Arun holds an MBA in Marketing & Operations from Bharathidasan Institute of Management, Trichy, and a B.E. in Mechanical Engineering from Anna University, Chennai.