【Major Industrial Equipment in the Chemical Industry】502—Replacement of imported plate heat exchangers with wound-tube heat exchangers for continuous reforming units from 2018 onward
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The last edit to this post was made by Desert Fish on 2022-8-21 at 10:21. The original design capacity of Hainan Refining & Chemical’s continuous reforming unit was 1.2 million tons per year; it was expanded to 1.44 million tons per year in 2013. This device plays an important “bridge” role in the process flow of Hainan Refining & Chemical Company; the oil it produces serves as the main raw material for the aromatic extraction unit, while the by-product hydrogen acts as the primary hydrogen source for the company. The reforming feed product heat exchanger is the core equipment of this process unit. Traditional processes generally use shell-and-tube heat exchangers, but such exchangers require strict conditions for starting up and shutting down, and are prone to uncontrolled problems during operational fluctuations. The original design of the continuous reforming unit at Hainan Refining & Chemical Company featured plate heat exchangers imported from France. Since it came online in 2006, it has been in operation for over 11 years; it has now reached its designed service life. As a result, its heat exchange efficiency has declined, with a temperature difference at the hot end reaching 57°C and a pressure drop of 120 KPa. This has significantly increased the energy consumption requirements of the four-in-one furnace, the product air cooler, and the circulation pump. During the major maintenance in 2013, the company discovered that the plate bundles of the heat exchangers had become deformed.
The selection of heat exchangers in continuous reforming units directly affects the stability and efficiency of the units. After thorough research and evaluation, Hainan Refining & Chemical replaced the inlet plate heat exchanger of its continuous reforming unit with domestically produced coiled tube heat exchangers during the unit’s shutdown for maintenance in 2017. These heat exchangers feature a simple and reliable design, strong resistance to fluctuations, and high heat exchange efficiency. Following the replacement, after nearly four months of operation, the equipment has functioned smoothly, with significant improvements in energy savings and efficiency. With the processing capacity and operating intensity of the reforming unit both higher than those in the same period last year, the temperature difference at the hot end decreased from 57°C to 25°C. The fuel gas consumption of the four-in-one furnace dropped from 2250 Nm3/h to 1300 Nm3/h, resulting in a savings of approximately 950 Nm3/h in fuel gas usage, representing a reduction rate of 42.2% ； The temperature of the product before air cooling dropped from 112°C to 94°C, reducing the load on air cooling and water cooling systems. Shutting down one air cooler saves 18.5 KW·h per hour, while reducing the water supply for air cooling saves approximately 3 tons of demineralized water per hour ； The pressure drop was reduced from 120 KPa to 80 KPa, allowing the cycle machine to save about 3 tons of steam per hour. Currently, the fuel gas usage, air cooling power consumption, and steam consumption in the reaction system of Hainan Refining & Chemical Company’s continuous reforming unit are showing an overall downward trend. With the unit operating at full capacity of 171 t/h and assuming an annual operating time of 8,400 hours, it is estimated that fuel gas costs can be saved by nearly 18 million yuan per year, while costs related to steam consumption and demineralized water can be reduced by over 4 million yuan; in total, this results in savings of 22 million yuan.
The 2.6 million tons per year continuous reforming unit at Hainan Refining & Chemical was put into operation. On January 6, the 2.6 million tons per year continuous reforming unit as part of Hainan Refining & Chemical’s 1 million tons per year ethylene and refining expansion project, which was constructed by the Fifth Construction Company for refining projects, officially began operations. The construction schedule for this facility is 482 days, and its main components include an 2.6 million tons per year continuous reforming unit, the plant’s process and thermal piping networks, a circulating water facility, the regional substation CS60, the 35/6/0.38V substation CS11 for the combined units, a wastewater treatment plant, a diesel hydrogenation feedstock tank area, HC and ARDS feedstock tank areas, as well as the renovation of the air compression station – totaling 18 different units.
It’s tough in the scorching summer heat! Keep up with heat prevention and cooling! Clarify the key tasks! Safety analysis must not be neglected! ----------------------------------------------The past decade has been a period of rapid development in China’s chemical industry, with the emergence of many new processes, products, and equipment. China’s chemical processing equipment has also seen significant progress, 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 localization of equipment. We invite everyone to share, discuss, and exchange ideas – let’s cheer for Made in China and support the development of chemical processing equipment! ------------------------------------------------------ 【Ministry of Emergency Management’s Special Inspection 2022】Summary Edition – welcome to participate in discussions and self-inspections! ! ! ! https://bbs.hcbbs.com/forum.php?mod=viewthread&tid=3418729 (Source: Huahai Chuanliu – Haichuan Network) Summary post for the 【Major Chemical Equipment in China】 series; being updated. https://bbs.hcbbs.com/thread-3366481-1-1.html (Source: Huahai Chuanliu – Haichuan Network)
What material is the heat exchanger made of? It can last for 11 years; are there any repairs or replacements needed during that time? I need to study hard so that I can teach customers how to maintain it in the same way