【Major Chemical Equipment】1.56–2.6 million tons/year fluidized bed residue forge-welded hydrogenation reactor
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This post was last edited by Desert Fish on 2022-5-5 14:56. Happy May Day! Reply reward! ---------------------------------------------- The past decade has been a period of rapid development in China’s chemical industry, marked by the emergence of many new processes, products, and equipment. There has also been significant progress in China’s chemical processing equipment, which has contributed to the swift advancement of the petrochemical sector. Here, we have compiled some of the achievements and breakthroughs made by Chinese equipment manufacturers in terms of larger-scale production and greater use of domestic equipment. We invite everyone to share their insights and discuss these topics together; let’s cheer for Made in China and support the development of chemical processing equipment! ****************** 2.6 million tons/year fluidized bed residue forge-welded hydrogenation reactor: On April 28, 2018, in Zhenjiang, Jiangsu, a 2.6 million tons/year fluidized bed residue forge-welded hydrogenation reactor was being lifted (shot by drone). On that day, in front of a dock in Zhenjiang, Jiangsu, three cranes worked together to lift a giant cylindrical container and transport it onto a shipping vessel that was already waiting by the river. This 2.6 million tons per year fluidized bed residue forge-welded hydrogenation reactor is the heaviest hydrogenation reactor in the world today. Its successful manufacture and shipment also mark the official launch of Sinomach Heavy Equipment Group Co., Ltd., the flagship enterprise in China’s high-end heavy equipment manufacturing sector. Hydrogenation reactors are commonly used to hydrogenate the heaviest fractions in the petroleum industry – residue – into lighter oils, thereby producing gasoline, diesel, and other products. The \"super\" hydrogenation reactor shipped this time weighs 2,400 tons in total, is over 70 meters long, and has an outer diameter of 5.4 meters; its weight as well as the complexity of its manufacturing process both break existing world records for hydrogenation reactors. Furthermore, its shipment set a new record for the heaviest lift ever carried on the Yangtze River waterway.
Zhenhai Refining & Chemical’s fluidized bed reactor, as well as Shenghong Refining & Chemical’s 1,915-ton reactor, were also manufactured by DONGYU.
It’s this one; one unit each for the first and second levels
On April 11, 2018, the world’s largest petrochemical technology equipment – the Zhenhai fluidized bed residue forge-welded hydrogenation reactor, manufactured by China National First Heavy Machinery Corporation – was completed and shipped from Dalian Nuclear Power Petrochemical Company. The successful production of this equipment marks once again China’s leadership in the manufacturing technology of ultra-large-tonnage petrochemical equipment on the international stage, demonstrating the strength of its major industrial capabilities. At the same time, it has added new momentum to the vigorous development of China’s petrochemical industry. 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 significant increase in the 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 reactor vessel weighs 2,400 tons and has a diameter of nearly 5 meters. Dalian Nuclear Power and Petrochemical Company in China earnestly implemented the new development philosophy and pursued high-quality development. Thanks to its strong R&D capabilities, advanced manufacturing technologies, and excellent market performance, it was tasked with developing this equipment in 2016. During the manufacturing process, due to the different structure of the fluidized bed reactor compared to traditional 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 too long and heavy, those that could not be heat-treated as a whole, issues related to radiographic testing, non-centrifugal pipe connections, and welding of dissimilar steel materials in all positions. As a result, the manufacturing tasks were completed efficiently and to high quality. The successful development of this device 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 efforts to localize major petrochemical technology equipment at this company. Relevant leaders and guests from Sinopec Zhenhai Refining & Chemical Co., Ltd. and China National Heavy Machinery Corporation Nuclear Power & Petrochemical Company were present to witness the completion and shipment of the Zhenhai hydrogenation reactor.
This hydrogenation reactor, developed by ERECO, a key manufacturing enterprise under SINOMACH Heavy Equipment Group Co., Ltd. which is part of China National Machinery Industry Corporation, is the first fluidized-bed residue hydrogenation reactor in China’s refining sector. It has set two \"world records\" for today’s hydrogen reactors: the first is a \"world record\" for the weight of the product – this hydrogen reactor has a total length of over 70 meters, an outer diameter of 5.4 meters, and a weight of 2,400 tons ； Secondly, it boasts the highest complexity in manufacturing technology in the world; both its manufacturing processes and level of complexity surpass the global records for manufacturing hydrogen reactors
Due to the product’s oversized size, heavy weight, and excessive dimensions, its transportation, lifting, and shipment set a new record for combined lifting operations in China – the total weight of the product along with the lifting equipment amounted to an astonishing 2,500 tons. SINOMACH Heavy Equipment Zhenjiang Company has two cranes with a lifting capacity of 850 tons each, resulting in a total lifting capacity of 1700 tons per lift. This is the highest lifting capacity on the Yangtze River waterway, and it is known as the \"best crane on the Yangtze River.\" And a weight of 2,500 tons far exceeds the maximum capacity of the \"largest crane on the Yangtze River\". To ensure the successful lifting and shipment, two 850-ton cranes and a 1600-ton self-propelled floating crane were used in combination for the lifting operation, setting a new record for the heaviest lift ever carried out on the Yangtze River waterway