The advanced petrochemical production process depends on advanced petrochemical equipment. Therefore, the development of petrochemical production technology must be equal to the development of equipment and technology. This article describes the technical status and trends of several typical petrochemical-specific and general-purpose equipment.
After more than 20 years of hard work, China's chemical equipment has achieved major technological development achievements. The key equipment required for major production plants such as catalytic cracking, hydrorefining and polyethylene has reached the international advanced level, reducing China's dependence on chemical equipment imports, reducing construction investment and production costs, and promoting petrochemicals. Industrial development plays an important role. Compared with foreign countries, there are still many gaps in China's chemical equipment, mainly chemical production technology development and equipment technology development out of touch, major equipment, a large gap between the development of software technology; equipment technology development can not keep up with the pace of technological development, heavy technology, The phenomenon of light equipment exists; basically it stays at the point of imitation development, and the ability to develop proprietary technologies with independent intellectual property rights is weak; equipment development cannot yet be specialized and serialized; equipment design and manufacturing level, equipment quality and reliability Sex still needs further improvement. With the progress and development of chemical process, higher requirements have been put forward for chemical equipment. It is necessary to increase the development of equipment, master the core technology of equipment, and form a group of equipment with independent intellectual property rights to achieve advanced performance, reliable quality, high efficiency and energy saving, economic security, and meet the development needs of the chemical industry.
one. Petrochemical special equipment
Petrochemical special equipment mainly includes reaction equipment, towers, heat exchange equipment, industrial furnaces, storage and transportation equipment and special machinery.
Reaction equipment
Reactor: A "heart" device that performs a chemical reaction process. Its development trend is different. Internationally, it has expanded from experience amplification to mathematical simulation to achieve large-scale, high-efficiency, simplification of the structure, and automation of operations. Research methods tend to be integrated.
Catalytic cracking reactor: Domestic manufacturing technology has basically reached the international advanced level and is widely used in various refineries.
Hydrogenation Reactor: Famous foreign manufacturers include Japan Steel and Kobe Steel. The domestic forging hydrogenation reactor developed for coal chemical industry has an outer diameter of 5500mm, a wall thickness of 340mm and a weight of 2040 tons. It is the heaviest hydrogenation reactor in the world, and its gap is poor innovation capability in China.
Continuously reforming four overlapping reactors: UOP patented U.S. technology enables the reactor to have advantages such as high reaction efficiency, energy saving, small footprint, and investment saving. Domestically, it has mastered its design and manufacturing technology, and internal fitting installation indicators fully meet the requirements of UOP technology.
Fertilizer ammonia synthesis tower: The international representative Kellogg horizontal synthesis tower, Topsoe vertical synthesis tower, Wood's vertical synthesis tower, and Brown's three adiabatic axial synthesis towers. On the basis of digestion and absorption in China, for the first time in the construction of a 200,000-ton/a-year ammonia plant, a single-layer forged, thick-walled outer cylinder with a diameter of 2.4 meters and a double-cone-sealed ammonia synthesis tower has not been fully mastered yet. Its design software also does not have the experience of designing and manufacturing 300,000 tons/year ammonia synthesis tower.
Polypropylene loop reactor: The famous manufacturer is Haimeng, and the reactor design technology and software are gradually mature. The 200,000-ton/year polypropylene loop reactor has been successfully developed in China and has been popularized and applied in Shanghai Petrochemical. The structural design of the loop reactor has been mastered, and the mathematical model of the combined stress calculation has been established. The technical problems of the loop reactor engineering amplification have been solved, and the technical level is equivalent to that of foreign countries.
High Pressure Polyethylene Plant Ultrahigh Pressure Tubular Reactors: Japan, Germany, the United States, and the Netherlands have mastered technology abroad: domestically developed 30,000 tons/year and 200,000 tons/year ultrahigh pressure tubular reactors through digestion and absorption. And coolers. Compared with foreign countries, there is a big gap between the performance of software development and design technology. Only the deep hole drilling method is used in China, and the material utilization rate is low. In addition, there are no special standards and ordering specifications.
Large-scale polymerization reactors: The technology of reactors with stirrers in foreign countries is relatively mature, and various types of stirrer structures can be developed according to different materials and parameter series. The domestically developed maximum polymerizer was a 70m3/year high-density polyethylene unit 90m3 polymerizer. The 100,000-ton/year polyester reactor has established a reaction rate model and process model for each process of esterification and polycondensation. The process technology software, as well as the reactor structure and heat transfer requirements, were proposed. The esterification reactor and polycondensation reactor developed for Yizheng Chemical Fiber have been put into production. The difference with foreign countries is mainly due to the small number of stirrers and weak selection capacity.
Heat exchange equipment
Heat exchangers are important equipment in petrochemical production. Almost all processes have heating, cooling or condensing processes and are therefore important energy-saving devices. With the large-scale and high-efficiency of industrial devices, foreign heat exchangers tend to be large-scaled, and they are developing in the direction of low temperature difference and low pressure loss.
The fin-and-fin heat exchanger (cold box): The cold box is mainly used in ethylene cracking, air separation, natural gas liquefaction, the key technology is design technology and manufacturing technology, the United States s-W company and Germany Linde and other technologies are more advanced mature . Hangzhou Oxygen Making Plant introduced the key processing equipment of the United States, a large-scale vacuum brazing furnace, which brought the design level and manufacturing capacity of the cold box to reach the international advanced level and was applied in the ethylene transformation of Yanshan, Yangtze, and Shanghai. There are 9.0 MPa cold box products in foreign countries. The design and manufacturing technology of high pressure cold box is not yet mastered in China. There is a big gap in the separation and fractionation technology.
Plate and shell heat exchangers: Only the French company Packinox can produce catalytic reforming and hydrogenation units with a maximum heat transfer area of ​​8000m2. The maximum heat transfer area developed in China is 3000m2. The main difference is that the developed monolithic area is the same, but the heat exchange area is small.
Waste Heat Boiler: It is an important energy-saving equipment. It is commonly used in the ethylene cracking and ammonia synthesis plant. German Borsig company and American Kellogg company technology are more advanced. The domestic focused on the development of integrated technology for floating-head waste heat boilers, and also carried out experimental research on key technologies for other types of converted gas, developed the overall design, the finite element calculation and analysis of the thin tube plate stress, and the numerical calculation of the internal circulation of the fire tube waste heat boiler. And the analysis and other large-scale procedures, the development of the first floating-head waste heat boiler for the Sichuan Chemical Plant 200,000 tons / year ammonia plant, but has not yet produced 300,000 tons / year conversion gas waste heat boiler.
After more than 20 years of hard work, China's chemical equipment has achieved major technological development achievements. The key equipment required for major production plants such as catalytic cracking, hydrorefining and polyethylene has reached the international advanced level, reducing China's dependence on chemical equipment imports, reducing construction investment and production costs, and promoting petrochemicals. Industrial development plays an important role. Compared with foreign countries, there are still many gaps in China's chemical equipment, mainly chemical production technology development and equipment technology development out of touch, major equipment, a large gap between the development of software technology; equipment technology development can not keep up with the pace of technological development, heavy technology, The phenomenon of light equipment exists; basically it stays at the point of imitation development, and the ability to develop proprietary technologies with independent intellectual property rights is weak; equipment development cannot yet be specialized and serialized; equipment design and manufacturing level, equipment quality and reliability Sex still needs further improvement. With the progress and development of chemical process, higher requirements have been put forward for chemical equipment. It is necessary to increase the development of equipment, master the core technology of equipment, and form a group of equipment with independent intellectual property rights to achieve advanced performance, reliable quality, high efficiency and energy saving, economic security, and meet the development needs of the chemical industry.
one. Petrochemical special equipment
Petrochemical special equipment mainly includes reaction equipment, towers, heat exchange equipment, industrial furnaces, storage and transportation equipment and special machinery.
Reaction equipment
Reactor: A "heart" device that performs a chemical reaction process. Its development trend is different. Internationally, it has expanded from experience amplification to mathematical simulation to achieve large-scale, high-efficiency, simplification of the structure, and automation of operations. Research methods tend to be integrated.
Catalytic cracking reactor: Domestic manufacturing technology has basically reached the international advanced level and is widely used in various refineries.
Hydrogenation Reactor: Famous foreign manufacturers include Japan Steel and Kobe Steel. The domestic forging hydrogenation reactor developed for coal chemical industry has an outer diameter of 5500mm, a wall thickness of 340mm and a weight of 2040 tons. It is the heaviest hydrogenation reactor in the world, and its gap is poor innovation capability in China.
Continuously reforming four overlapping reactors: UOP patented U.S. technology enables the reactor to have advantages such as high reaction efficiency, energy saving, small footprint, and investment saving. Domestically, it has mastered its design and manufacturing technology, and internal fitting installation indicators fully meet the requirements of UOP technology.
Fertilizer ammonia synthesis tower: The international representative Kellogg horizontal synthesis tower, Topsoe vertical synthesis tower, Wood's vertical synthesis tower, and Brown's three adiabatic axial synthesis towers. On the basis of digestion and absorption in China, for the first time in the construction of a 200,000-ton/a-year ammonia plant, a single-layer forged, thick-walled outer cylinder with a diameter of 2.4 meters and a double-cone-sealed ammonia synthesis tower has not been fully mastered yet. Its design software also does not have the experience of designing and manufacturing 300,000 tons/year ammonia synthesis tower.
Polypropylene loop reactor: The famous manufacturer is Haimeng, and the reactor design technology and software are gradually mature. The 200,000-ton/year polypropylene loop reactor has been successfully developed in China and has been popularized and applied in Shanghai Petrochemical. The structural design of the loop reactor has been mastered, and the mathematical model of the combined stress calculation has been established. The technical problems of the loop reactor engineering amplification have been solved, and the technical level is equivalent to that of foreign countries.
High Pressure Polyethylene Plant Ultrahigh Pressure Tubular Reactors: Japan, Germany, the United States, and the Netherlands have mastered technology abroad: domestically developed 30,000 tons/year and 200,000 tons/year ultrahigh pressure tubular reactors through digestion and absorption. And coolers. Compared with foreign countries, there is a big gap between the performance of software development and design technology. Only the deep hole drilling method is used in China, and the material utilization rate is low. In addition, there are no special standards and ordering specifications.
Large-scale polymerization reactors: The technology of reactors with stirrers in foreign countries is relatively mature, and various types of stirrer structures can be developed according to different materials and parameter series. The domestically developed maximum polymerizer was a 70m3/year high-density polyethylene unit 90m3 polymerizer. The 100,000-ton/year polyester reactor has established a reaction rate model and process model for each process of esterification and polycondensation. The process technology software, as well as the reactor structure and heat transfer requirements, were proposed. The esterification reactor and polycondensation reactor developed for Yizheng Chemical Fiber have been put into production. The difference with foreign countries is mainly due to the small number of stirrers and weak selection capacity.
Heat exchange equipment
Heat exchangers are important equipment in petrochemical production. Almost all processes have heating, cooling or condensing processes and are therefore important energy-saving devices. With the large-scale and high-efficiency of industrial devices, foreign heat exchangers tend to be large-scaled, and they are developing in the direction of low temperature difference and low pressure loss.
The fin-and-fin heat exchanger (cold box): The cold box is mainly used in ethylene cracking, air separation, natural gas liquefaction, the key technology is design technology and manufacturing technology, the United States s-W company and Germany Linde and other technologies are more advanced mature . Hangzhou Oxygen Making Plant introduced the key processing equipment of the United States, a large-scale vacuum brazing furnace, which brought the design level and manufacturing capacity of the cold box to reach the international advanced level and was applied in the ethylene transformation of Yanshan, Yangtze, and Shanghai. There are 9.0 MPa cold box products in foreign countries. The design and manufacturing technology of high pressure cold box is not yet mastered in China. There is a big gap in the separation and fractionation technology.
Plate and shell heat exchangers: Only the French company Packinox can produce catalytic reforming and hydrogenation units with a maximum heat transfer area of ​​8000m2. The maximum heat transfer area developed in China is 3000m2. The main difference is that the developed monolithic area is the same, but the heat exchange area is small.
Waste Heat Boiler: It is an important energy-saving equipment. It is commonly used in the ethylene cracking and ammonia synthesis plant. German Borsig company and American Kellogg company technology are more advanced. The domestic focused on the development of integrated technology for floating-head waste heat boilers, and also carried out experimental research on key technologies for other types of converted gas, developed the overall design, the finite element calculation and analysis of the thin tube plate stress, and the numerical calculation of the internal circulation of the fire tube waste heat boiler. And the analysis and other large-scale procedures, the development of the first floating-head waste heat boiler for the Sichuan Chemical Plant 200,000 tons / year ammonia plant, but has not yet produced 300,000 tons / year conversion gas waste heat boiler.