The Zhenhai fluidized bed residue forge-welded hydrogenation reactor was successfully completed
Thread Content
According to a report in the Heilongjiang Daily on April 11, the Zhenhai fluidized-bed residue forge-welded hydrogenation reactor, the world’s largest crude oil processing facility built by China National First Heavy Machinery Group Corporation (abbreviated as \"China First Heavy\"), has been successfully completed! The emergence of this technological equipment signifies that China leads the world in the manufacturing technology of petrochemical crude oil processing equipment such as ultra-large-tonnage fluidized-bed residue forge-welded hydrogenation reactors, once again achieving the top position globally. Not only is it massive in size and powerful in functionality, but it also generates revenues in the hundreds of billions – truly a major asset for any great nation!
A fluidized bed residue forge-welded hydrogenation reactor is, in essence, a petrochemical device that mixes crude oil residue with hydrogen, feeds it in from the bottom of the reactor, where processes such as catalysis, refining, and internal/external circulation take place, thereby maintaining a fluidized state. It is possible to fully refine residue, **increase its conversion rate, reduce the load on delayed coking, and boost the production of light oils. Moreover, the Zhenhai fluidized bed residue forge-welded hydrogenation reactor has far more functions than that; it can also process various petrochemical products such as vacuum residue and asphalt.
Why use forge welding? Can’t it be welded with plates?
Forged and welded products of large-scale components represent the manufacturing capabilities of major countries, and only a very few countries in the world **possess such capabilities.
What size press is needed for this? Is it for welding the shell, or welding the head?
Head forging and welding. This was manufactured at a factory on Mianhua Island in Dalian.
Advances in the technology of hot-wall hydrogenation reactors with forged and welded structures in our country https://bbs.hcbbs.com/forum.php?mod=viewthread&tid=1963754 (Source: Haichuan Chemical Industry Forum)
I read the article in the attachment, but I didn’t understand what the purpose of forge welding is. Is it used for forge welding composite panels – different from explosive welding? ?
The Zhenhai fluidized-bed residue forge-welded hydrogenation reactor is the most critical equipment in the 2.6 million tons per year upgrading project carried out by Sinopec Zhenhai Refining & Chemical Co., Ltd. Once this project is completed and put into operation, it will enable a higher conversion rate of residue, reduce the load on delayed coking units, and thus create new sources of profit growth for Sinopec Zhenhai Refining & Chemical Co., Ltd. The equipment manufacturing contract was signed in October 2016. The reactor vessel weighs 2,400 tons, has a diameter of nearly 5 meters, a wall thickness of over 300 millimeters, and a length of about 70 meters. Its design temperature is as high as 430°C, and it can withstand pressures of nearly 20 MPa. As a key state-owned enterprise in China, China National Heavy Machinery Corporation earnestly implements the new development philosophy and adheres to high-quality development. Thanks to its strong R&D capabilities, advanced manufacturing technologies, and excellent market performance, it was entrusted with the task of developing this equipment. During the manufacturing process, due to the fact that the structure of the fluidized bed reactor differs from that of conventional fixed-bed reactors, the installation of its internal components is complex, requires high precision in processing, and makes manufacturing extremely difficult. Through rigorous project management, strict adherence to technical specifications, and thorough quality control, the skilled technicians and frontline workers, combined with their excellent manufacturing skills and diligent work ethic, overcame numerous challenges such as reactors that were excessively long and heavy, those that could not be heat-treated as a whole, issues related to radiographic inspection, non-centrifugal pipe connections, and welding of different types of steel in all positions using stainless steel pipes. As a result, the manufacturing tasks were completed efficiently and to high quality. Its successful production not only enhanced China National Heavy Machinery Corporation’s capabilities in specialization, innovation, and core competitiveness, but it also set a new record for the development of ultra-large-tonnage forged-welded hydrogenation reactors in our country, opening a new chapter in the localization of major petrochemical technology equipment by this company.
I visited the manufacturing process on Cotton Island before and didn’t understand it...
It’s really amazing to forge and weld such thick large-diameter tube sections and heads!