【Haichuan Expands Horizons】1,200-ton Dongguo furnace successfully manufactured – world’s largest dry coal powder radiation waste-gas furnace in single-unit configuration

The gasifier is the key equipment in the coal chemical industry used to convert coal into syngas; it features reactions that take place under high temperature and pressure with pure oxygen, at temperatures as high as 1300°C, resulting in liquid slag and the raw material gas required for downstream chemical processes – syngas (CO+H2). Due to the harsh reaction conditions, conventional gasifiers generally do not undergo direct heat exchange after the reaction, but instead use water spraying for cooling. The gasifier in the radiation waste boiler process features an innovatively added radiation heat exchange section at the outlet of the high-temperature syngas, which absorbs the heat energy at high temperatures; this improves the overall thermal efficiency of the gasifier, making it the most advanced gasifier design available in the industry today. It is also the type of gasification furnace with the most complex structure and largest size.

When lifting this equipment using just one lifting point, how accurate must the center of gravity be?

The structure of this equipment (especially its internal components) is extremely complex, its manufacturing is difficult, and the production timeline is tight. Its successful production marks a significant breakthrough for Dongfang Boiler in the manufacturing of radiation waste boiler gasifiers, demonstrating the company’s strong manufacturing capabilities in this sector. It represents a new milestone in the production of core equipment for large-scale chemical projects, and it has provided Dongfang Boiler with valuable experience and a solid foundation for mass-producing such gasifiers. 　　Since taking on the responsibility for manufacturing this gasifier, Dongfang Boiler has always adhered to high standards, rigorous requirements, and a high starting point. Leveraging its strong technical capabilities, advanced manufacturing processes, and comprehensive quality assurance system, it has successfully carried out numerous evaluations of specialized welding techniques that involve high technical challenges, and has worked on developing solutions for the use of new materials, thereby advancing its production activities steadily. 　　Faced with numerous challenges such as controlling deformation in ultra-large-diameter structures, extremely complex internal component designs, great difficulties in welding, and the impact of the COVID-19 pandemic, the employees rushed back to work as soon as possible. By leveraging their intelligence and working together in a coordinated manner, they developed detailed manufacturing plans, held regular weekly meetings to address various issues that arose during production, and provided 24/7 equipment support services. The workshops responsible for manufacturing the shells and internal components worked overtime, struggled hard to overcome obstacles, and ensured seamless coordination between different stages of production. This allowed them to effectively surmount difficulties such as tight deadlines, complex welding requirements, and the effects of the pandemic. Through strict project management, adherence to technical specifications, and rigorous quality control, they successfully completed the manufacturing of this gasifier, making a significant contribution to the development of large-scale chemical equipment manufacturing in China. The successful production of this gasifier has once again set a new manufacturing record for Dongfang Boiler in the field of gasifiers, further demonstrating the company’s superior capabilities as a manufacturer of high-end equipment for major industrial applications, and laying a solid foundation for the continued development of its market presence.

Wugang Iron and Steel’s steel plates were used to build the world’s first dry coal powder, waste-boiler-type gasification furnace. Category: Company News. Author: Source: Wugang Daily. Publication date: 2019-07-17 14:40. On July 15, Wugang Iron and Steel successfully secured an order for 948 tons of high-grade chromium-molybdenum steel with a thickness of 145 millimeters, which is suitable for use in hydrogen-rich environments. This steel will be used to manufacture the furnace shell, a key component of the world’s first dry coal powder waste-boiler-type gasifier, which is being developed by China Dongfang Electric Corporation. 　　Hebei Iron and Steel Wugang remains committed to the specialty steel route, driving product upgrades in response to the needs of high-end customers. Upon learning that the company’s key client, China Dongfang Electric Group, was responsible for developing the world’s first dry coal powder waste-boiler-type gasification furnace – specifically for the demonstration project of the new materials integration facility at Shanghai Huayi Group’s site in Qinzhou, Guangxi – Hebei Wuhan Iron and Steel Company immediately organized its technical service team to engage in in-depth technical discussions with the manufacturers, design institutes, and project owners. In response to the client’s various additional requirements regarding the use of steel in critical components of this gasification furnace, such as high thickness levels, low-temperature impact resistance, and specific performance tests, the company developed specialized process and technical standards to facilitate trial production and problem-solving. During the development process, advanced material design concepts were employed, the timing of adding raw materials was optimized, and the proportions of alloying elements were strictly controlled to ensure that the composition and purity of the molten steel met the customer’s requirements ； In the rolling and heat treatment stages, 3 new processes were innovatively adopted, and various technical challenges such as the difficulty in ensuring the rolling properties of steel plates and surface cracks were successfully overcome. As a result, high-density chromium-molybdenum steel plates suitable for hydrogen service with high technical requirements were developed, and their performance exceeded the customer’s specifications, which earned high recognition from the customers and led to the acquisition of orders for 948 tons of such high-density chromium-molybdenum steel plates with a thickness of 145 millimeters. (Dong Jie, Huang Zhuqing)

This type of furnace is definitely high-tech; ordinary companies do not have the capability to manufacture it.

Dongfang Boiler has had its Chemical Machinery Branch handling this task for a long time; this report is about Dongfang Boiler using the facilities provided by DAEWOO in Zhenjiang to carry out this work

The core internal components of the Huayi gasifier are manufactured in two sections: the gasification chamber section and the radiant waste heat boiler section. The production of radiation waste boiler sections is difficult, requires high-grade materials, imposes strict requirements on weld joint alignment, and there is no space for welding. Faced with these challenges, the water wall workshop worked closely with relevant departments to pool their ideas. The welding of the most difficult-to-weld part, namely the roof of the old boiler, was carried out in four stages, with each section manufactured separately before being assembled together and connected to the radiation shield. Through hard work and perseverance in overcoming difficulties, all 3,515 radiation waste boiler joint welds and 3,025 gasifier joint welds were successfully completed, with the first-time inspection pass rate for these welds exceeding 95%