At present, the design and production technology of large-scale ethylene complete sets of equipment in the world is increasingly perfect, mainly reflected in the following four aspects:
First, ethylene cracking furnaces are rapidly developing. At present, the production scale of ethylene cracking furnaces in the world has reached 150,000 to 200,000 tons/year, and the cracking furnace technology is continuously being reformed and increasingly perfected. It is now moving towards large scale, low investment, low raw material consumption, low energy consumption and long operating cycle. , advanced control technology and simulation design and other direction.
Second, the research and development of gas compressors. The technical development trend of gas compressors in the world is to develop compressors with higher processing capacity and higher operating characteristic parameters; the theoretical research will be gradually microscopic and the model development will be non-linear; the overall machine efficiency will be more than 82%, and continuous failure-free. Run for 3 years. At present, the major foreign manufacturers of large-scale ethylene three-engine design and manufacturing are: American Dreiserin, German Siemens (acquisition of Demag-Drava Turbine), German Gehaha-Boschig Turbomachinery, Mitsubishi, Japan Heavy Industry Co., Ltd., Hitachi, Ltd., Japan.
Third, the development of ethylene cold boxes. The international ethylene cold box technology continues to advance. For example, the application of composite refrigerants and fractional condensation fractionation technology has higher requirements on the performance and technical parameters of ethylene cold box, and the fractionation and fractionation technology is the future direction of development. Plate-fin heat exchangers have a design temperature of -190°C and a maximum pressure of 8.7Mpa. A set of 800,000-ton/year ethylene cracker requires about 20 plate-fin heat exchangers. The number of flow channels can reach up to 15 streams, and there are more phase transitions.
Fourth, the production of extrusion granulators. At present, only the German WP company, Japan Steel Corporation, Japan Kobe Steel, and the United States Farrell have large-scale extrusion granulation unit design, manufacture, installation and commissioning technology.
Technical route: Perfecting independent innovation policy support system
Wang Tingjun pointed out that the difficulty in designing and manufacturing large-scale ethylene equipments of millions of tons is unprecedented. There are still many gaps in domestic design and manufacturing levels compared with foreign countries, and some equipment cannot be designed and manufactured at present in China. At the time of the arrival of a new upsurge in China’s ethylene industry construction, if China does not seize the opportunity to tackle the problem, China’s major ethylene equipment will be subject to long-term control.
China already has a technological basis
Since the 1980s, the country has listed 300,000 tons/year of ethylene equipment as the focus of research and development. It has organized domestic research, design, manufacture, and user integration, adopting imported design and manufacturing technologies, technology and trade, cooperation design, and cooperation. The method of manufacturing has made breakthroughs and achieved fruitful results. According to the calculation, the localization rate has reached 70%, which has laid a foundation for overcoming a million-ton large-scale ethylene complete set of equipment, and has also trained a group of technical cadres.
The way to achieve independent innovation
Wang Tingjun believes that to realize the localization of large-scale ethylene equipment of one million tons, we must first adopt the methods of independent innovation or digestion and absorption of imported technology, and use the results of technological breakthroughs over the years to make the localization of large-scale ethylene equipment reach a new level. .
Second is the need for national support, to determine the localization of relying on the project, through expert demonstration of the provisions of the proportion of localization of equipment, tendering to determine the major equipment development units, research and development units of technological transformation, research funding, tax preferential policies.
The third is to organize scientific research, design, manufacture, and use units to jointly tackle key problems and reward organizations and individuals that have made significant contributions.
The fourth is the use of units to do enlightened users, support the localization of major equipment, and cooperate with the development of manufacturing enterprises. At the same time, in order to reduce risks, the state must give preferential policies to the users in respect of taxation, risk compensation, etc.
The fifth is to standardize the petrochemical equipment technology policy and reduce the petrochemical major equipment independent innovation resistance. For example, the development of petrochemical major equipment must be technologically advanced and economically reasonable. The introduction and development of major petrochemical equipment must be carried out simultaneously. Different types of major equipment must adopt different policies to speed up the adjustment of major equipment bidding policies.
R&D Trend: Development of Environmental Protection, Energy Saving, and Large-scale Development
Wang Tingjun introduced to reporters that the general development trend of large-scale ethylene equipment is: in order to pursue low investment, low cost, low consumption, and improve project competitiveness, petrochemical process technology has been continuously introduced and the production scale is increasing, which will promote the development of petrochemical equipment. Change.
It is understood that the single-line production capacity of the international ethylene cracker has reached 1.27 million tons/year, and the single-line production capacity of polyethylene and polypropylene equipment has reached 500,000 tons/year. The large-scale petrochemical plant has effectively promoted the development of technologies such as the design and manufacture of petrochemical equipment as well as the research and development of high-performance new materials.
With the ever-changing development of petrochemical process technology, in order to constantly adapt to the new requirements of petrochemical process technology for petrochemical equipment, the combination of petrochemical equipment development and process technology design has become increasingly close, and together form proprietary and patented technologies, which has become common among foreign patents. Practices and trends. At the same time, mechatronics is a major trend in the development of the petrochemical equipment industry, involving technologies such as machinery, electronics, optics, control, computers, and information.
Wang Tingjun pointed out that future petrochemical equipment will be an intelligent system integrating high performance, high raw material utilization, low energy consumption, low pollution, environmental comfort and recyclability. As the petrochemical industry is a resource and energy-intensive industry and a highly polluting industry, the development of energy-saving and environment-friendly petrochemical equipment has become the development trend of the world's petrochemical equipment manufacturing industry. Since most petrochemical equipment is operated under high temperature, high pressure and corrosive conditions, the application of new materials can significantly improve the mechanical properties of materials, reduce the weight of equipment, reduce the cost, and facilitate transportation.
Although China's petrochemical major equipment manufacturing industry has made significant progress since the reform and opening up, there are still many gaps compared with the international industry, mainly reflected in: weak independent innovation capability, high external dependence, unreasonable industrial structure, and international competition The problem is not strong and the overall quality is not high.
At present, the one-million-ton large-scale ethylene plant equipment technology represents the highest level of petrochemical equipment in the world, and its localization will inevitably greatly increase the innovation capability of China's petrochemical equipment manufacturing industry, narrowing the gap between China's petrochemical equipment manufacturing industry and the world's advanced level.
Advantageous enterprises: Some technologies still need external force
In the development of major ethylene equipment, Beijing Petrochemical Engineering Company has had years of experience in the design of ethylene crackers. They continuously digested and innovated 20,000 tons/year, 40,000 tons/year, and 60,000 tons/year to 100,000 tons/year in various scales and furnace types. Currently, they cooperated with foreign countries to develop 150,000 to 20 Million / year ethylene cracking furnace, they can fully undertake the work of the one million tons large-scale ethylene cracker.
The radiant section furnace tubes, convection section furnace tubes, induced draft fans and burners in the cracking furnaces, etc., domestic companies have also had mature experience. The design and manufacture of waste heat boilers in cracking furnaces is still quite difficult and needs further research.
The compressors in the 1 million-ton large-scale ethylene, domestic Shenyang blower plant, Hangzhou turbine plant, Shenyang gas compressor plant, Shanghai compressor plant, and Wuxi compressor plant have many years of design and manufacturing experience and can undertake development tasks.
Hangzhou Oxygen Machine Factory has many years of experience in designing and manufacturing large-scale ethylene cold boxes. It can undertake the task of manufacturing large-scale ethylene cold boxes with a capacity of one million tons, but it must also strive to overcome the difficulties of the 8 MPa cold box.
Tower and storage and transportation equipment in a one-million-ton large-scale ethylene plant, domestic one, two-tier, Lanzhou petrochemical machinery plant, Dalian Jinzhou Heavy Machinery Plant, Nanhua Company Machinery Plant, Shanghai Boiler Plant, Shanghai Petrochemical Machinery Companies such as manufacturing companies can afford it completely.
The chemical pump in the large-scale ethylene plant of one million tons has developed high-temperature and high-pressure feed pumps, high-speed pumps, cryogenic pumps, canned pumps, and chemical process pumps for refining and petrochemical plants in the past 20 years, filling the domestic gap. Petrochemical pump manufacturers mainly include Shenyang Pump Factory, Dalian Sulzer Pump Factory, Shanghai Kaishibi Pump Factory, Tianjin Acid-resistant Pump Factory, Benxi Pump Factory, Changsha Industrial Pump Factory, Chongqing Pump Factory, and Zhejiang Jialit Pump Factory. In addition to special pumps, most of the domestic production is possible.
For the extrusion granulation unit, the domestic Dalian Rubber and Plastic Machinery Plant has been researching for many years, and has cooperated with foreign countries to manufacture parts in the 70,000-ton extrusion granulating machine, but there is no overall design and manufacturing technology and experience and it needs further development. Cooperation with foreign countries or independent innovation, master its core technology.
Typical Enterprise: Shenyang Blower Group
Shenyang Blower Group is a leading company in the field of domestic gas compressors. Since the 1970s, Shengu has introduced a full set of design and manufacturing patents for its three centrifugal compressor series: MCL, BCL, and PCL. After more than 20 years of digestion and absorption, it has mastered the core of imported technology and is constantly developing and innovating. At present, Shen Drum has made major breakthroughs in the aspects of compressor gas dynamics, rotor dynamics, and heat transfer, key technologies have been updated, and large-scale gas compressor sets in the production of oil refining, chemical, chemical fiber, and chemical fertilizers have been developed.
In the late 1990s, Shengu began to develop the "three machines" in the 300,000-ton/year ethylene plant - cracking gas compressors, propylene compressors, ethylene compressors (or three-way refrigeration compressors). There are: Cracking gas compressor of Daqing 480000 tons / year ethylene modification project (equivalent to 240,000 tons grade), Cracking gas compressor of Shanghai 720,000 tons / year ethylene transformation project (equivalent to 350,000 tons grade). In the last two years, Shengu has developed a cracking gas compressor (equivalent to 600,000 tons) in Maoming's 1 million tons/year ethylene transformation project. In addition, the refrigerating compressors and ethylene compressors developed by Shengu have been applied to Daqing, Yangzi, Yanshan, Shanghai and Maoming ethylene renovation projects.
Domestic domestic complete sets of key equipment for ethylene still need external force (2)
International frontier: design and manufacturing technology is increasingly perfect