【Ten Years of Rapid Development in Chemical Processing Equipment】Integrated Formation of 55-ton HHA6040*125mm Hemispherical Heads from 1172 to 2023

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This post was last edited by Desert Fish on 2023-10-6 at 07:45. Looking back at the decade-long development of chemical technology, celebrating the prosperity and strength of modern China. This is just a starting point; more participation will make it more lively. HaiChuan becomes even better with you here. [A decade of progress in chemical equipment] – a continuously updated summary thread; feel free to join the discussions: https://bbs.hcbbs.com/thread-3576046-1-1.html. Happy National Day! ! ! In February 2023, the hemispherical heads made of material Q345R and weighing over 55 tons each, manufactured by Henan Shenzhou Jinggong, were successfully formed in one go using a 39,000-ton intelligent double-acting press for use in coal chemical applications by Ningxia Baofeng Energy. This represents the first success in China in carrying out the overall forming of such large and thick hemispherical parts, and it marks another milestone in the field of manufacturing large and thick head components through stamping processes. As soon as the production order was received, faced with the core challenges of a hemispherical component weighing over 55 tons, having a stretching height of nearly 3 meters, requiring specialized mold design, ensuring proper welding quality of the material sheets, maintaining flatness, and controlling thermal treatment-induced deformations, the process and production staff held discussions to develop a plan. They carefully planned the head-forming process, thoroughly organized the preliminary preparations, the sequence of various steps, and the precautions to be taken, and came up with feasible solutions for each issue in order to address them all. In terms of the forming method, due to the large weight and significant deformation of the head, a three-stage hot stamping process was employed to reduce the amount of deformation per stage for the hemisphere and to ensure the appropriate stamping temperature for the head ； Regarding the design of mold components, careful consideration was given to meeting all of the customer’s dimensional requirements while reducing costs associated with mold flanging and pull rings. Therefore, a double-layer shell was used as a base to create a simple upper die, and by drawing on past experience, the existing pull rings and flanging elements were modified. Through scientific design of clearance fits, these elements were integrated to work in conjunction with the upper die ； Given the large degree of hemispherical deformation in this case, welding quality is of paramount importance as part of the preparatory work before shaping. If cracks occur in the welds during the stamping process, the consequences can be severe. Therefore, to ensure the welding quality and the flatness of the parts after welding, production staff assign skilled welders to carry out the welding using appropriate methods, while strictly controlling parameters such as temperature, current, and speed. Additionally, dedicated personnel are assigned to oversee this process ； To address the issue of difficult control over deformation during heat treatment, faced with head heights exceeding 3 meters, strict tolerances on ellipticity, and rigorous requirements regarding diameter size, technicians determined the position and distance of the supports inside the furnace, ensuring the proper positioning of the heads in a static state and thereby reducing their deformation during heat treatment. Each challenge marks the beginning of a step forward. The head design, which utilizes overall stamping, prevents the formation of numerous welds that would result from segmented pressing. This not only significantly reduces the workload related to welding and inspection, as well as the time required for assembly and welding before and after traditional forming processes, but it also lowers costs for customers. At the same time, it enhances the quality of the core components of the equipment, providing a solid guarantee for the safe and long-term stable operation of large-scale installations. The successful completion of this project not only demonstrates Shenzhou Head’s unwavering commitment to its strategic focus on internationalization, high-end development, and the use of special materials, but it also highlights the company’s strength in areas such as technical research and process design. By successfully solving various challenges faced by its clients, Shenzhou Head is fulfilling its vision of becoming a trusted provider of head solutions worldwide.