【Ten Years of Rapid Development in Chemical Equipment】The methanol synthesis tower for China’s first 500,000 tons/year coal-based ethanol project, 1984–2021
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The last edit to this post was made by Desert Fish on January 26, 2023, at 22:43. There has been significant development in chemical processing equipment over the past decade; may China continue to thrive and prosper. Wishing everyone a happy New Year, and may their families be safe and healthy. I hope this post will inspire further discussion from everyone – with more participants, the forum will become even more lively. Haichuan is better with you all here; feel free to participate more in discussions on this forum. ********************************************** The methanol synthesis tower for China’s first 500,000-ton/year coal-based ethanol production project, manufactured by Xini Nuclear Equipment, successfully passed the factory inspection at the beginning of June 2021, and was then shipped out. The equipment is of a shell-and-tube reactor design; it has a diameter of 4 meters, a total length of approximately 18.3 meters, and a net weight of around 250 tons. The Party committee of Xiniuke Equipment Company attaches great importance to this matter, organizes production carefully, arranges the production processes in an orderly manner, and ensures strict compliance with safety and quality standards ； Departments such as the machine processing branch work together closely and in a coordinated manner; technical inspectors provide continuous monitoring, inspection, and guidance to ensure smooth operations on the production front line ； The civil products division places implementing production plans as a top priority; the personnel involved in manufacturing provide full support to production, voluntarily giving up their holiday time to actively participate in the process of inserting tubes into heat exchangers. After 8 months of joint efforts, the methanol synthesis tower was successfully completed on May 24, 2021. The successful production of the methanol synthesis tower for China’s first 500,000 tons per year coal-based ethanol project marks another achievement for Xiniu Equipment in the manufacturing of such towers, laying a solid foundation for undertaking similar projects in the future. Taking this as an opportunity, Xiniuke Equipment will make every effort to complete all production tasks for 2021 in a high-quality and efficient manner.
The methanol synthesis tower is a shell-and-tube reactor with a diameter of 4 meters, a total length of 15 meters, a net weight of 230 tons, and heat exchange tubes that are 7 meters long. To ensure product quality and on-time delivery, the Special Equipment Division holds coordination meetings on a weekly basis to effectively plan production and allocate resources. It arranges the manufacturing processes properly, assigns experienced welders and riveters to carry out the assembly and welding of equipment. The manual and automatic welding teams strictly follow the specified procedures during welding, completing all welds with high quality; the first-pass qualification rate for radiographic inspection is 100%. This approach helps to reduce costs and shorten production times, thus fulfilling the quality goal of \"getting things done right the first time.\"
During the manufacturing process, the Special Equipment Division utilized an innovative method of saddle cutting followed by saddle welding, which **reduced welding time, improved welding quality, and led to a significant increase in labor productivity. By modifying the submerged arc welding trolley and innovating welding methods, the automatic welding team managed to carry out automatic welding of the inner seams at the two joints where the upper and lower end caps meet the cylinder body. This approach **reduced the workload on the welders, and the welding quality met the technical requirements. The success of this welding process optimization and welding equipment modification provides valuable experience for welding similar equipment in the future. The successful completion of the methanol synthesis tower further enhances the company’s competitiveness in the coal chemical industry. Taking this as an opportunity, the Special Equipment Division will, with a high sense of responsibility and strict execution standards, focus on the civilian products market. Adhering to the customer-centric philosophy and leveraging its own strengths, it will make its due contribution to the high-quality development of nuclear equipment.
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Thank you for sharing; kudos to technological progress