In 2005, China’s ethylene production capacity was 9 million tons/year. According to relevant departments’ forecast, China’s ethylene demand will reach 25 million to 26 million tons in 2010, and the production capacity will reach 14 million tons/year, which can only meet domestic demand. %. In 2020, China's ethylene demand will reach 37 million to 41 million tons, and the production capacity will reach 23 million tons per year, which can only meet 60% of domestic demand. According to the preliminary forecast, by 2010, China will need to add 7-8 sets of ethylene units of 800,000 to 1 million tons. By 2020, China will need to add about 9 sets of ethylene equipment of 800,000 to 1 million tons.
It is understood that the large-scale ethylene projects that have been approved for construction include Zhejiang Zhenhai Petrochemical's 1 million tons/year ethylene project, with a total investment of 23.3 billion yuan, completed in 2009; Fujian Quanzhou 800,000 tons/year ethylene project has started construction with a total investment of 266 yuan. Billion yuan was completed in 2008; Tianjin Petrochemical's 1 million-ton/year ethylene project has been approved for construction, with a total investment of RMB 20.1 billion and completed in 2008; Sichuan Chengdu’s 800,000-ton/year ethylene project has been approved by the state with a total investment of RMB 21 billion. Completed in 2010. The 600,000-ton/year ethylene renovation project in Lanzhou is underway. The investment is 6.3 billion yuan and it will be completed in 2006. The pending ethylene projects include Guangzhou Petrochemical's 800,000-ton ethylene project, Fushun Petrochemical's 800,000-ton ethylene project, Xinjiang Dushanzi's 1 million-ton ethylene project, and Wuhan Petrochemical's 800,000-ton ethylene project.
Wang Tingjun introduced that a large-scale ethylene plant with a capacity of one million tons is to be built. The total investment is generally more than 20 billion yuan. According to the historical experience, the cost of equipment accounts for 30% of the total investment, and the equipment cost for each large-scale ethylene project will be Reached 7 billion yuan. Therefore, it is expected that during the “Eleventh Five-Year Plan†period, China will have about 56 billion yuan in ethylene equipment market demand, and during the “12th Five-Year Plan†period there will be 63 billion yuan in the equipment market.
Domestic situation: Six key equipments to be tackled
The first major equipment: ethylene cracking furnace
According to Wang Tingjun, in the past, ethylene cracking furnaces were patented equipment abroad. In order to break through the foreign technology blockade, the domestic ethylene cracking furnaces have made unremitting efforts to design and manufacture 20,000 tons/year, 40,000 tons/year, and 60,000. Ton/year CBL furnace and 100,000 tons/year SL furnace have been applied in the technical transformation of old ethylene plants. In order to meet the needs of one million tons of ethylene production, the current domestic research and design units are cooperating with foreign countries to develop 150,000 to 200,000 tons/year of large-scale ethylene cracking furnaces.
The second largest equipment: gas compressors
Gas compressors in large-scale ethylene plants are numerous, and the most important ones are ethylene "three machines", ie, cracked gas compressors, propylene compressors, ethylene compressors (or three-way refrigeration compressors). They are the "heart" equipment of the ethylene cracker. They have complex technical requirements and are expensive. The total cost of the three machines is more than 200 million yuan. At present, there are technical bases for the development of 800,000 to 1 million tons/year of large-scale ethylene machines in China. However, due to the large-scale compressors, the real-state equations of gas state and physical property parameters in thermodynamics and software program development are also needed. More work is being done on R&D aspects such as automatic control systems.
Among the ethylene plants, the reciprocating labyrinth seal compressors in polyethylene and polypropylene plants are also used in many applications. The labyrinth seal compressor technology has matured abroad, but research and development in the country is only a matter of recent years. The labyrinth seal compressor developed by Wuxi Compressor Factory has been applied to 100,000 tons/year linear low density polyethylene devices. In order to meet the needs of millions of tons of large-scale ethylene equipment, it is necessary to develop a large multi-row labyrinth seal compressor. The secondary compressor in the high-pressure polyethylene plant is the UHP reciprocating compressor with the highest discharge pressure currently in use in China and cannot be designed and manufactured in China.
The third largest equipment: ethylene cold box
The ethylene cold box is a combination of plate-fin heat exchangers. It is understood that the domestic Hangzhou Oxygen Making Machine Factory has introduced the large-scale vacuum brazing furnace of the design technology and key processing equipment of the United States SW, which has brought the design level and manufacturing capacity of the cold box to approach and reached the international advanced level. Since the production of monomer spare parts in 1992, Hangzhou Oxygen Plant has designed and manufactured 9 sets of large and small ethylene cold boxes and dozens of single spare parts, ending the history that domestic ethylene cold boxes are completely dependent on imports from abroad. At present, Hangzhou Oxygen has produced a large number of ethylene cold boxes for Yanshan Petrochemical, Yangzi Petrochemical, Shanghai Petrochemical, Qilu Petrochemical, and Maoming Petrochemical. Therefore, domestic production of 800,000 to 1 million tons per year of large-scale ethylene cold box has basically met the conditions, the next step is to develop a design pressure of 8MPa ethylene cold box to meet the needs of a variety of petrochemical production processes.
The fourth largest equipment: polymerization reactor
The key equipment for the polyethylene and polypropylene plant is the polymerization reactor. The structure is different depending on the production process. Basically, there are three types of kettle-type stirred reactors, tower reactors and tubular reactors. Wang Tingjun introduced that because of the close relationship between reactors and production processes, most of these reactors are patented equipment in the world. At present, no tower gas phase reactors can be designed in China. However, the 250,000-ton polyethylene gas phase reactors designed and manufactured in China have been used in the 700,000-ton/year ethylene transformation projects in Shanghai and Nanjing.
At present, there is not yet a complete understanding of the design of high-pressure tubular reactor technology for designing high-pressure polyethylene units in China, but equipment manufacturing has already gained experience. The domestic 200,000-ton/year ultrahigh-pressure polyethylene tubular reactor has been used in Yanshan Petrochemical Company, and the domestic 300,000-ton/year polypropylene loop reactor has been applied to Maoming Petrochemical. However, large-diameter pipes cannot be produced domestically, and the pipe wall thickness tolerance and ellipticity requirements are very high. It is still difficult for domestic steel pipe manufacturers to achieve.
The fifth largest equipment: extrusion granulator
Extrusion granulators are major equipment in post-processing equipment for polyethylene and polypropylene plants. Wang Tingjun introduced that at present, China has cooperated with foreign countries to manufacture 70,000 tons of extrusion granulators, but there is no performance. The large-size extrusion granulation unit requires a production capacity of over 50 tons/hour, equivalent to 300,000 tons/year, and it is difficult to design and manufacture itself, which requires the introduction of technology or co-production. At present, the international price of large-scale extrusion granulators is very expensive. The price of a single unit is about 5 million US dollars. China will continue to introduce it during the “Eleventh Five-Year Plan†period, but it is necessary to start research early.
Sixth largest equipment: DCS automatic control system
The automatic control system of a million-ton large-scale ethylene plant generally adopts a distributed control system (DCS), and the control loop of a single device reaches 300 to 1,000. The DCS system of petrochemical enterprises' production facilities is currently mainly imported from abroad. Among them, Yokogawa's products account for 1/3, Honeywell's products account for 1/3, and the others are Foxboro, ABB, and Italy. Lee's products. Domestic efforts have also been made to tackle the problem. It was used on petrochemical production equipment and auxiliary production equipment with few control loops. However, it has not been further studied and industrialized. It has now been imported.
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