Control Valves Up to 4,000 Bar – Precise Flow Control Under Extreme Pressure

High-pressure systems leave no room for compromise in valve technology. KAMAT develops and manufactures control valves for process pressures up to 4,000 bar, used in oil and gas production, mining, water jetting, and steel processing. All valves are manufactured in Germany, ATEX-certified, and designed for operation on high-pressure plunger pumps with flow rates up to 4,000 l/min. Request a technical consultation or configure your solution directly.

A control valve in a hydraulic system regulates the flow of a liquid medium: it determines whether a flow path is open or blocked, the direction in which the medium flows, and the volume passing through. In certain designs, the valve also directly influences the pressure of the high-pressure system.

In standard industrial hydraulics and pneumatics, control valves are designed for pressures up to a few hundred bar at most. High-pressure applications place fundamentally different demands on the technology: housing wall thicknesses, sealing surfaces, and material selection must be engineered for forces at which standard valves fail through leakage or material fatigue. Control valves for high-pressure technology are therefore not scaled-up standard products but dedicated product lines with pressure-rated forged housings, adapted sealing concepts, and media-compatible materials.

Control valves can be divided into two basic designs based on their closure construction: seat valves and spool valves. Which design is appropriate for a given application depends on operating pressure, the medium, and the requirements for leak-free performance and switching speed.

Seat valves

Seat valves close by direct contact of a closure element against a valve seat. This construction creates a metallic or soft-seat sealing edge that remains leak-free even under very high pressures. For high-pressure applications above several hundred bar, seat valves are the preferred design because the acting pressure forces support the sealing function rather than working against it. KAMAT high-pressure valves are based on this principle and are rated for pressures up to 4,000 bar.

Spool valves

Spool valves control flow through the axial or rotary movement of a spool within the housing. They allow flexible switching functions with multiple ports and positions and are widely used in standard hydraulics. In the high-pressure range, spool valves are more complex to engineer, as the tight fits between spool and housing must be both pressure-resistant and low-friction. For process pressures above 700 bar, they are less commonly used.

Directional control valves

Directional control valves are a specific sub-group within control valves. They control exclusively the flow direction of the medium and are classified by the number of ports and switching positions, for example as 2/2 or 3/2 directional control valves.

The actuation type determines response time, control signal, and suitability for specific operating environments. In high-pressure units, the forces required for switching are considerably greater than in standard hydraulics, which directly influences the design of the actuation elements.

• Pneumatic actuation: Pneumatically actuated control valves switch via a compressed air impulse on a control piston. They respond quickly, are insensitive to electromagnetic interference, and are suited to potentially explosive atmospheres. In high-pressure applications they are frequently used as pilot valves that switch a larger main valve.
• Hydraulic actuation (pilot control): In pilot control, a separate control pressure circuit at a lower pressure level actuates the main valve. This enables reliable switching under very high working pressures without exposing the actuation elements to full system pressure. Pilot-controlled valves are the preferred solution for high switching frequencies and strongly varying flow rates.
• Electric actuation (solenoid valve): Solenoid valves switch via an electromagnet and can be integrated directly into PLC architectures. KAMAT supplies electrically actuated control valves in ATEX versions for potentially explosive environments, such as in oil and gas production or mining.
• Manual actuation: Manually actuated control valves are switched via handwheel or lever and are used wherever no automated control is required. In the high-pressure range, they are designed so that operating forces remain manageable despite high pressures, for example through mechanical gearing or pressure relief before opening.

• Oil and gas production: In the oil and gas industry, high-pressure valves control the flow of aggressive media under extreme pressure. Leak-free performance and ATEX compliance are not optional here. KAMAT control valves are available in ATEX versions for exactly this requirement profile.
• Mining: In mining, high-pressure valves control water hydraulic systems for longwall support systems and pump stations with up to 2,500 kW total capacity. Robustness, ease of maintenance, and ATEX compliance are the governing design criteria.
• Water jetting and industrial cleaning: In water jetting, control valves release the high-pressure jet, interrupt it, and distribute it to multiple consumers, at pressures ranging from several hundred to over 2,500 bar. Fast switching times and absolute leak-free closure are prerequisites for safe operation.
• Descaling and waterjet cutting: Control valves time the process, manage the pressure build-up curve, and ensure pressureless standstill between working strokes — in descaling systems up to 400 bar and in waterjet cutting up to 2,500 bar. KAMAT supplies valve solutions designed for high switching frequency and abrasive media.

KAMAT has been developing and manufacturing high-pressure control valves for over four decades, matched to operation on high-pressure plunger pumps and in complex system solutions. The portfolio covers 2/2 and 3/2 directional control valves, pneumatically, hydraulically, and electrically actuated versions, as well as manually operated variants.

• Pressure range up to 4,000 bar, flow rates up to 4,000 l/min: The valves are designed for the demands of industrial high-pressure processes where standard valves fail. Individual system solutions such as KAMJET Pump Skids reach pressures up to 4,000 bar.
• Manufactured in Germany: All valves are developed and produced at the Witten site. Quality assurance and manufacturing depth are entirely in-house.
• CE and ATEX certified: All valves meet CE requirements. ATEX-certified versions are available for use in potentially explosive atmospheres, such as in oil and gas production or underground mining.
• Materials for aggressive and abrasive media: For applications involving corrosive media or abrasive components, versions in adapted materials are available, matched to the specific chemical and mechanical loads of the respective process.
• Multi-consumer systems: KAMAT control valves are designed for operation in systems where a single high-pressure source supplies multiple consumers in parallel, without pressure drop or control inaccuracies.
• Modular component system: KAMAT applies a modular system across the entire valve portfolio. Common parts are used across product lines, simplifying spare parts management, shortening delivery times, and reducing service effort in the field.

Pressure rating, actuation type, port geometry, and certification can be adapted on a project-specific basis. KAMAT implements special versions for applications that cannot be covered by standard valves. Contact our sales team or configure your solution directly in the pump finder.