Process Solenoid Valves

Take a look at our process solenoid valves at ValveMan—designed for accurate control in challenging fluid and gas-handling systems. These solenoid valves are specifically designed to handle aggressive media, high temperatures, and corrosive environments, so they are excellent solutions for chemical processing, pharmaceutical, and industrial automations applications. Direct acting, pilot operated, and specialty solenoid valve types in a range of sizes, materials, and voltage options. Looking for the best valve? Our experts will help you or find exactly what you need.

Process Solenoid Valves

A process solenoid is an electromechanical device that controls the flow of liquids or gases using a simple electrical signal to power an electromagnet. They are essential for automated flow systems. 

The solenoid part of the valve is essentially an electromagnetic coil with a plunger and seal. The coil creates a magnetic field when current passes through it. When magnetized, it pulls a metal plunger (a spindle) up or down to control the flow. 

The plunger is attached to a seal that will either block or unblock one or more orifices in the valve body. The seal is typically made from NBR, EPDM, or Viton, depending on the media involved. The valve body is usually manufactured from brass, stainless steel, or a polymer such as PTFE. 

Common Process Solenoid Valve Configurations

Process Solenoid Valves can be classified according to their default state or how many ports they have. Here’s a summary of default states:

  • Normally Closed (NC): valve stays closed until power is applied (most common for safety)
  • Normally Open (NO): valve stays open and only closes when powered
  • Latching (Bi-stable): Uses a pulse of power to open and another to close; stays in its last position without constant electricity (which is great for battery-powered systems)

Solenoids can also be classified by the number of ports and ways: 

  • 2-Way: 1 Inlet, 1 Outlet: Used for simple On/Off control
  • 3-Way: 3 Ports: Used to divert flow from one path to another or to vent pressure from an actuator
  • 4-Way / 5-Way: Primarily used to control hydraulic or pneumatic cylinders (5-Way is pneumatic only)

Direct-Acting Process Solenoid Valves

Direct-acting solenoid valves are among the most reliable and simplest. They get their name from the fact that the plunger is directly connected to the valve disc. When the electromagnetic coil is energized, the seal is lifted directly from the seat. 

One of the features that sets direct-acting process solenoid valves apart from others is that they operate from zero pressure, which means they don’t require any help from the fluid pressure to open. This makes them a great option for low-pressure systems, small pipe sizes under 1”, and vacuum applications. In addition, they offer an extremely fast response time and have fewer moving parts that can fail. They are, however, limited in size. As the pipe size or pressure increases, the coil would need to be much larger to overcome the force resisting the metal plunger and seal.

Pilot-Operated Process Solenoid Valves

Pilot-operated process solenoid valves, also known as servo-assisted valves, use the pressure of the fluid. The solenoid only has to open a tiny pilot hole that creates the pressure imbalance needed to force the main piston or diaphragm to open. They do require a minimum pressure differential to operate, usually between 5 and 15 psi. If the pressure happens to be low, the valve may not be able to fully open or stay open. 

These solenoid valves work best for high-pressure and high flow applications that involve larger pipe sizes. In fact, they can control very large flows using just a small, low-power coil. On the other hand, they are going to have a slower response time than direct-acting solenoid valves.

Speciality Process Solenoid Valves

This refers to a very broad category of solenoid valves that are needed when general-purpose valves would fail. Here are some examples:

Type

Specialized Feature

Typical Application

Cryogenic

Materials (like PTFE) that don't shatter at -320°F.

Liquid Nitrogen, Liquid CO2.

Steam / High Temp

Heat-resistant coils and metal seals.

Sterilizers, industrial boilers.

Explosion-Proof

Heavy-duty housing to contain internal sparks.

Oil refineries, chemical plants.

Proportional

Varies the flow based on voltage (not just On/Off).

Precise gas mixing, burner control.

NAMUR Mount

Specific bolt pattern to mount directly to actuators.

Automated ball/butterfly valves.

Intrinsically Safe

Limits electrical energy to prevent ignition.

Hazardous "Zone 0" environments.

ValveMan is your one-stop shop for all your process solenoid valve needs. Our team of experts can help you configure the valve components you need – and if you don't see what you're looking for, just ask us, and we’ll source and order it. ValveMan is waiting to hear from you!

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