[Chemical Equipment Powerful Country] 269-Using its own 36,000-ton vertical extrusion machine to manufacture P91 and P92 steel pipes
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This post was last edited by Yuyu in the Desert on 2022-5-23 21:47 Chemical Workers’ Red May! Reply rewards! ---------------------------------------------- The past ten years have been an era of great development for China's chemical industry. The emergence of many new processes, new products, and new equipment has also led to a great development in my country's chemical equipment, which has also promoted the rapid development of the petrochemical industry. Here we have collected and sorted out some of the achievements and breakthroughs made by my country's equipment companies in the large-scale and localization of equipment. Welcome everyone to share, discuss, and exchange, cheer for Made in China, and cheer for chemical equipment! ===================== Throughout the ages, competition between countries is essentially competition between equipment manufacturing industries. At the current stage, high-end equipment has become the core and indispensable weapon in the game between major powers. History will never forget this moment: On July 13, 2009, at the hot test site of the 36,000-ton ferrous metal vertical extruder (referred to as "Project 360") of China Ordnance Industry Group Beizhong Group, with an order, the 36,000-ton vertical extruder started to move steadily, and then a flaming red steel pipe emerged from the top of the extruder. In an instant, everyone at the scene clapped excitedly. This moment is of great significance, this moment is what everyone expected. It marks that my country's heavy-duty extrusion and material forming technology has broken the long-term monopoly of foreign countries, and heralds the spring of development of my country's high-end material forming technology. Sure enough, more than 10 years of hard work has borne fruit. With the "Spring Thunder" of the "360 Project", China's high-end seamless steel pipe industry has grown from scratch to strength, not only breaking the monopoly of foreign technologies, but also forcing the global price system of related products to make major adjustments. ； With the "spring thunder" of "Project 360", the P91 and P92 steel pipes extruded by "Project 360" flew into major power plants across China like spring swallows after the rain. They have repeatedly made breakthroughs in applications in aviation, marine engineering, military industry and civil fields. They have also rushed out of the country and opened a new chapter in leap-forward development.……
Turn back time to the late 1990s. It was a time when shame accompanies rise. At that time, my country's social and economic development began to enter the fast lane. Large thermal power plants were built one after another, and large ships were born in the docks.…… * * The demand for large steel, especially large seamless steel pipes, is increasing day by day. In sharp contrast to the increasing demand, the production capacity of my country's large-scale steel manufacturing industry: Because heavy-duty extrusion technology is the core processing technology for high-performance and difficult-to-process materials, the process is complex and the equipment construction is extremely difficult. At that time, large-scale extrusion technology had been monopolized by foreign companies. Almost all products used in related industries in my country relied on imports, and these products were extremely expensive. Based on the price of more than 20,000 US dollars per ton at that time, the price of an imported seamless steel pipe was even more than that of a top-end car! The high cost has seriously restricted the development of my country's thermal power industry and manufacturing industry.
People in Beizhong will always remember the painful pain! In 2004, the company solved the problem of * * Supply issues of key materials began to be sought and developed * * Carry out technical cooperation on the "vertical extrusion large-diameter thick-walled seamless steel pipe project". However, the American Wyman & Gordon Company, which has the world's exclusive technology monopoly, is very tough. They believe that extrusion technology is the basis for its survival, and it is impossible to transfer the technology. Moreover, joint ventures and cooperation in this technology require the United States to * * Approval, therefore directly rejected Beizhong people’s request for negotiation ； The German SMS Meer company, which claims to have design capabilities, has an arrogant attitude. They ask for exorbitant prices. The preliminary design plan only costs about 100 million euros for the extrusion machine! The high prices make Beizhong people feel passive and helpless.
In 2006, the "360 Project" was officially launched. As the project leader, Lei Bingwang led the team to officially start their arduous journey of exploration. As the largest vertical extrusion press project in the world at the time, there was very little domestic experience that could be used for reference. Lei Bingwang remembers clearly that at that time, the only things available for research and reference were atlases of foreign large-scale extrusion press products and theoretical materials from the Soviet Union. There was only one relevant domestic theoretical material, "Special-Shaped Steel Pipe Production." Even if there is only this one, it is a treasure for him and the R&D team. With a stack of paper, a pen, and several professional books, the accumulation of professional knowledge by Lei Bingwang and his team was carried out under limited conditions. The books became older and older as they were read, and the knowledge accumulated became deeper and deeper. In order to verify the extrusion process learned in books, he went through great troubles to find Professor Fang Yuandong, the author of "Special-shaped Steel Pipe Production", and found the Shanghai Special-shaped Steel Pipe Factory, which was the first in the country to extrudate small special-shaped steel pipes. Through simulation optimization and scale-down experimental verification, he successfully completed the design and development of the extrusion process, laying a technological foundation for equipment development.
In the eyes of colleagues, Lei Bingwang's working status at that time can be described as "crazy": The mobile phone is not turned off 24 hours a day and can answer calls from staff at any time. ； I haven’t taken a vacation for 3 consecutive years, and I focus exclusively on technical research. ； When researching technical information, I often sit all morning. I don’t realize it until my colleagues remind me that it’s lunch time. I keep talking about power and pressure while walking on the road... This is a history of arduous struggle, and at the same time, it is also a collaborative piece of wisdom and cohesion. Manufacturing 10,000-ton heavy equipment is a * * It is a sign of manufacturing capabilities that involves many technical difficulties such as design, manufacturing, transportation, and installation, and belongs to the field of "extreme manufacturing". Facing the company's unprecedented scientific research, Lei Bingwang knew that relying on his own team alone was too weak. Only by concentrating the advantages of industry, academia and research and adopting an integrated and innovative R&D model could key breakthroughs be achieved.
When the equipment enters the installation period, whether the "big thing" of the steel wire prestressed winding frame can be accurately installed in place becomes the key to the success of the project. Through repeated demonstrations by Lei Bingwang’s team members and installation implementation unit technicians, the 36,000-ton extrusion frame weighing nearly 3,000 tons was successfully built on the foundation, achieving a major innovation in large-scale press manufacturing and installation technology, which not only provided * * It saved a lot of foreign exchange and ensured the rapid completion of the project. In fact, during the entire process of project implementation, there were many difficulties like this. Everyone gathered firewood and the flames were high. Through collective efforts, the team led by Lei Bingwang completed the seven-year workload of similar foreign equipment in just three years. In the past three years, they have made breakthroughs in key technologies such as press design, large-scale casting and forging manufacturing, large-scale overweight frame steel wire prestressed in-situ winding, main cylinder manufacturing, overweight frame overall installation, oversized hydraulic system installation and debugging, equipment installation and debugging, etc., and created many world firsts. Split assembly and steel wire prestressed winding technology have been engineered on large-scale equipment, which has opened up a new way to solve the problem of extreme insufficient manufacturing capacity of 10,000-ton heavy equipment in my country. It is of great significance to promote the revitalization of my country's manufacturing industry and the leap-forward development of manufacturing capabilities.
The extrusion production line, heat treatment production line, finishing production line, mold repair production line and supporting public and auxiliary facilities were completed and put into operation... With the improvement and commissioning of each equipment production line, one after another new processes and new products were nurtured and incubated. In 2014, Beizhong Group successfully completed the P92 localization demonstration project for the four major pipelines of Huaneng Nantong Power Plant's million-kilowatt unit, marking a comprehensive breakthrough in the technology of high-end heat-resistant steel large-diameter thick-walled seamless steel pipes for the four major domestic ultra-supercritical units. Beizhong Group became the first provider of P92 seamless steel pipe localization demonstration projects.