Retrofitting for Success in the Cement Industry
- Matt DelPizzo
- 11 minutes ago
- 3 min read
In the high-stakes world of cement production, downtime isn’t just an inconvenience—it’s a massive drain on the bottom line. For decades, the industry relied on heavy, bulky cast-style diverter valves to route abrasive materials through pneumatic conveying lines. However, as production demands increase and maintenance windows shrink, these legacy "monoliths" are becoming a liability.
At Delta Ducon, we recently addressed this challenge head-on at a major cement production facility in the Southeast United States. By replacing an outdated competitor's unit with our 12" PERMA/flo® KG Diverter Valve, we didn't just swap a part; we engineered a strategic upgrade that has been optimizing material routing and slash-and-burning maintenance costs since going operational in October 2025.
The Problem: The High Cost of Legacy Equipment
The facility was struggling with a legacy cast diverter that had become a bottleneck. While these older units were once the industry standard, they carry several inherent flaws for modern operations:
Prohibitive Lead Times: When a cast body fails, the wait for a replacement can take months, risking extended plant outages.
Maintenance Intensity: These units are often "all-or-nothing." If one internal component wears out, the entire heavy casting often needs to be pulled, repaired, or replaced.
Excessive Weight and Footprint: Their bulky design makes them difficult to install in tight spots and requires heavy structural support.
The Solution: The PERMA/flo® KG Diverter Advantage
The PERMA/flo® KG Series was specifically engineered for the "abrasive extremes" found in cement, mining, and power generation. Unlike a single-body cast valve, the KG Diverter utilizes a modular approach that offers superior flexibility and durability.
1. Engineered for Extreme Abrasion
Cement and clinker are notoriously unforgiving. To combat this, the KG Diverter is constructed with our proprietary 400+ BHN P-33 Alloy or PERMA/flo® II induction-hardened steel. This ensures the internal flow paths can withstand high-velocity abrasive particles far longer than standard carbon steel or basic cast iron.
2. Modular Efficiency
The KG design consists of a 45-degree lateral and two independently pneumatically actuated knife gate valves. This modularity is a game-changer for plant managers:
Ease of Service: Individual components can be serviced without dismantling the entire assembly.
Reduced Spares Inventory: You only need to stock common parts rather than a massive, expensive cast housing.
3. Precision Sealing and Dust Control
Cross-contamination and material loss are common issues with worn flapper-style diverters. The KG Diverter maintains a reliable, dust-tight seal on the closed leg. This precision ensures that 100% of your material goes exactly where it's supposed to, maintaining system pressure and process integrity.
4. Streamlined Footprint
Despite its ruggedness, the KG Diverter offers a compact, modern profile. In our recent Southeast installation, this streamlined footprint allowed for a much cleaner integration into the existing conveying line, simplifying the retrofit process and reducing the need for additional structural reinforcement.
Real-World Results
Since the October 2025 commissioning, the facility has reported a significant improvement in system uptime. By moving away from the "legacy cast" mindset, they have secured a Made-in-USA solution that offers:
Feature | Legacy Cast Diverters | Delta Ducon KG Diverter |
Lead Time | Often 20+ Weeks | Industry-Leading Delivery |
Maintenance | Complex / Heavy Lift | Modular / Field-Serviceable |
Seal Integrity | Prone to Leaking over time | Precision Knife Gate Sealing |
Wear Resistance | Standard Cast Iron | 400+ BHN P-33 Alloy |
Engineering Your Next Retrofit
At Delta Ducon, we bring over 100 years of experience to every project. We understand that in the cement industry, you don't just need a valve—you need a solution that survives the environment. Whether you are handling fly ash, clinker, or raw meal, our engineering team is ready to help you transition from outdated legacy equipment to high-performance, abrasion-resistant technology.
Is your current diverter valve a ticking time bomb for your production schedule?
