【Ten Years of Rapid Development in Chemical Equipment】From 1631 to 2022: The first domestic-produced ethylene feed pump for DMTO units was successfully developed in China!
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Happy May Day 2024! Safety first. Let’s give praise and support to the achievements made in China’s chemical engineering technology and equipment. **********************【Ten Years of Progress in Chemical Engineering Equipment】A continuously updated summary post is available; feel free to join the discussions at https://bbs.hcbbs.com/thread-3576046-1-1.html (Source: Haichuan Chemical Engineering Forum) ***************** In August 2022, the first set of ethylene feed pumps for domestic methanol-to-olefins (DMTO) plants, designed and developed by Danai Pump Co., Ltd., was successfully installed, tested, and put into operation on August 4th. To date, all performance indicators are normal, with the vibration speed at 0.6 mm/s, which is at an internationally advanced level. This marks the localization of the first ethylene feed pump for domestic DMTO units. As one of the core equipment in DMTO plants, the safe, reliable, and long-term stable operation of the ethylene feed pump is of utmost importance. In the past, our country has relied on imports for this product for a long time. As the technology and manufacturing standards of the domestic pump industry improve, localization has become inevitable. When two of the imported pumps in Tianjin Bohua’s 1.8 million tons per year methanol-to-olefins plant failed and had to be taken out of service one after another, Dainai Pump Industry rushed to produce the replacement pumps despite the pressure of a one-month delivery deadline. With the full cooperation of suppliers for mechanical seals and other related components, the delivery was ultimately completed within the agreed time frame. It is reported that this pump features low flow rate, high head, and low medium temperature under operation. As a key equipment in the DMTO plant, this pump requires high standards in terms of design, manufacturing, and maintenance. During the manufacturing process, Dainai Pump Industry pays close attention to every aspect of this project – including processes, procurement, machining, assembly, testing, and quality assurance – to ensure the precision of the components. The pump features a single-axis design with an axis length of 4100 millimeters. To ensure its stable operation, the design requires that the total runout of the pump shaft be 0.025 millimeters, which is well below the 0.08 millimeters specified by the API610 standard. By exercising strict control over every stage, from raw materials and heat treatment to machining, Dalian Pump Industry manages to achieve a runout value of 0.02 millimeters. It is understood that this pump is a vertical tubular bag multi-stage pump with a total of 11 stages, ranking among those with the highest number of stages. At the same time, the pump has a special structure, numerous components, and high precision requirements for each component. To produce high-quality products, Dainai Pump Industry develops thorough technical solutions from the initial design stage, and utilizes ANSYS analysis methods for verification to ensure the stable operation of the pumps through proper design.
Low-carbon olefins (ethylene, propylene) are the cornerstone of the modern chemical industry; they serve as the basic raw materials for various important synthetic materials such as plastics and fibers. The scale of production of low-carbon olefins is an indicator of the development level of the petrochemical industry and an economy as a whole. With the continuous and rapid development of China’s national economy, there is an increasing demand for low-carbon olefins, which in turn leads to a growing demand for DMTO as a production facility for such olefins. As one of the core equipment in DMTO plants, the safe, reliable, and long-term stable operation of the ethylene feed pump is of utmost importance; in the past, reliance on imports meant that there was a high risk of being held back by supply constraints. With the technological advancement and improvement in manufacturing standards within the domestic pump industry, localization has become inevitable. As a leading domestic manufacturer of petrochemical pumps, Danai Pump Industry has taken the initiative to get involved in the development of domestic technological innovations at an early stage. With its strong technical foundation and dedication to the pump industry, Dalian Pump Industry has built a comprehensive technical portfolio for ethylene feed pumps. When two of the imported pumps in Tianjin Bohua’s 1.8 million tons per year methanol-to-olefins plant failed and had to be shut down one after another, Danai Pump Industry won the trust of the plant owner thanks to its excellent brand reputation and long-standing track record of quality in the industry; the owner contacted Danai right away for assistance. Under the dual pressures of a delivery deadline of just one month and high quality standards, Dainai took the lead and without hesitation made a commitment to complete the task on time and to the required standard! This pump is characterized by low flow rate, high head, and low medium temperature. Being a critical piece of equipment, safety, reliability, and long-term stable operation are of particular importance, which imposes high demands on the design, manufacturing, and maintenance of such pumps. Since imported pumps are used on site, the foundations, cables, and various connections remain unchanged, which imposes higher and stricter requirements on the technical aspects – accurate measurements at the site must be ensured; otherwise, installation there will not be possible. This pump is a vertical tubular bag multi-stage pump with 11 stages in total, ranking among those with the highest number of stages. At the same time, due to the structural characteristics of pump design – which involves a large number of components – higher precision requirements are imposed on each of these components. To create high-quality and even sophisticated products, a thorough technical plan was developed from the initial design stage, and the ANSYS analysis method was used for verification to ensure the stable operation of the pump through proper design.
During the production process, considerable attention was paid to this project at every stage (process design, procurement, machining, assembly, testing, and quality assurance), ensuring that the precision of all components was maintained to high standards. It is worth mentioning that this pump features a single-axis structure with an axis length of 4100 mm. To ensure its stable operation, the design requires that the total runout of the pump shaft be 0.025 mm, which is well below the 0.08 mm specified by the API610 standard. Through strict control at every stage, from raw material selection and heat treatment to machining, the final runout value was achieved at 0.02 mm. This project is of a temporary emergency nature, with a delivery time of only 1 month (the usual delivery time is 6 months, and for imported pumps it’s even 8–12 months), which is quite demanding for the manufacturing department. Thanks to its large-scale operations and solid foundation, as well as advanced management methods – by reusing components from inventory and other projects for the castings, and accelerating the production of other parts – and with the full cooperation of suppliers such as those specializing in mechanical seals, Dainai was able to complete the delivery within the agreed time frame.
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