【Ten Years of Rapid Development in Chemical Equipment】The first domestic gasification full-heat recovery waste boiler was put into operation between 2010 and 2023
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This post was last edited by Desert Fish on 2023-7-11 at 13:43. Ten years of remarkable progress in chemical technology – let’s celebrate the prosperity and strength of modern China. This is just a starting point; more participation from everyone will make things even more lively. The forum becomes better with your involvement, so we welcome everyone to join in the discussions. Be careful with fire as the heat of July increases. ---------------------------------------------- In June 2023, Harbin Boiler Factory Co., Ltd., part of Harbin Electric Group (referred to as Harbin Electric Boiler), developed China’s first gasifier with full-process sensible heat recovery, along with radiation and convection waste heat boilers. These devices were successfully used in the Shenghong Refining project during its first operation, delivering excellent performance and economic indicators; their application technology is at the international leading level. The successful development of the equipment for the Shenghong refining project has significantly improved the utilization rate of coal in the coal chemical industry, greatly reduced the amount of water needed for cooling, and made it more energy-efficient and environmentally friendly. The application of the technology in these devices can increase the efficiency of hot gas utilization in coal chemical enterprises by 10%–95%, reduce energy consumption across the entire process by 9%–10%, and lower energy consumption in semi-waste boilers by 7%–8%. Taking the Shenghong Refining and Chemical Project as an example, the gasification sensible heat recovery unit is capable of handling an effective gas flow rate of 700,000 Nm3/h (CO+); it can produce 440 tons/h of superheated steam at a temperature of 520 degrees Celsius. This setup allows for the savings of nearly 500,000 tons of coal per year as fuel, and it helps to reduce carbon dioxide emissions by around 1 million tons. It brings significant economic and social benefits, and is of great importance in contributing to the development of China’s ecological civilization and the successful achievement of its ‘dual carbon’ goals. To further promote energy conservation and carbon reduction in the coal chemical industry, Harbin Electric Boilers, relying on the \"863\" project \"Development of Key Equipment for Sensible Heat Recovery in Integrated Gasification Combined Cycle\" as well as Harbin Electric Group’s flagship project \"Development and Application of Key Equipment for Sensible Heat Recovery in Large-Scale Coal Chemical Plants\", has entered into a exclusive partnership with Aerospace Maiwei Technology Company. Aiming to develop new green and low-carbon technologies and equipment, and making full use of the capabilities of central state-owned enterprises to overcome technical challenges, it has developed an internationally leading technical system suitable for energy savings, water conservation, environmental protection, as well as reduction of coal consumption and carbon emissions in the coal chemical industry. The application of this technical system has filled the technological gap in China’s field of full heat recovery for large-scale coal gasification, promoted the development of technologies related to waste boiler processes in large-scale coal chemical industries as well as related industries, and enhanced China’s international competitiveness and influence in the field of sensible heat recovery for coal gasification. Through technological breakthroughs and innovation, Harbin Electric Boilers has developed a technical framework that covers both full-waste-heat recovery and semi-waste-heat recovery processes in the field of gasification heat recovery. This has enhanced its equipment manufacturing capabilities and contributed to the development of larger-scale, high-parameter chemical processing equipment in China.
From 2008 to 2019, China’s coal chemical industry experienced rapid development. Against the backdrop of the rapid development of coal chemical industry in our country, Harbin Electric Boilers has made full use of its expertise in boiler and pressure vessel technology. Addressing the issue of low utilization of sensible heat in traditional gasification processes, it took on the leadership role in carrying out the research project titled \"Development of Key Equipment for Sensible Heat Recovery in Integrated Gasification Combined Cycle\", as part of the \"863\" Program. Upon receiving the task, Harbin Electric Boilers, in collaboration with Harbin Institute of Technology, the Institute of Engineering Thermophysics of the Chinese Academy of Sciences, and other institutions, actively carried out research and development on heat recovery systems as well as the key equipment involved, such as radiant waste boilers and convective waste boilers. A series of fundamental studies were conducted, including research on heat transfer characteristics under pressurized conditions and on the condensation mechanism of alkali metals in reducing atmospheres. At the same time, the company conducted an in-depth analysis of the development experience gained by the Shanxi Institute of Coal Chemistry, Chinese Academy of Sciences, in relation to multi-stage bed gasification systems. On this basis, the company carried out industrial testing of its heat recovery technology. The pilot plant developed was successfully commissioned in July 2013 and passed the on-site inspection successfully, marking the company’s successful completion of the task assigned under the **\"863\" program, specifically the development of key equipment for heat recovery in integrated gasification combined cycle systems. Thereafter, the Harbin Electric boiler technology team refined the technical plan repeatedly, using the data from pilot tests; they paid attention to every parameter and every detail. With a determined attitude and a commitment to persistent effort, they went all out to complete the marathon and relay race of developing full-heat recovery technology for gasification.
In 2019, Harbin Electric Boilers entered into a exclusive partnership with Aerospace Maiwei Technology Company to leverage gasification technology and make every effort to develop the first large-scale powder gasification with full heat recovery system in China for use in the Shenghong refining project – specifically, radiant waste boilers and convective waste boilers. The technical solution for this equipment adopts an advanced design concept focused on carbon reduction throughout the entire process. By leveraging years of research findings, it designs the sensible heat recovery process in a manner that takes into account the heat transfer characteristics in different temperature ranges. It represents the first full heat recovery solution in the industry with the widest temperature range coverage and the largest scale. The implementation of this scheme enables the recovery and utilization of all the sensible heat from the high-temperature syngas, which is above 1300 degrees Celsius and below 400 degrees Celsius. The period from 2020 to 2022 was a crucial time for advancing total heat recovery technology, and it was also a difficult period during which the company had to cope with the challenges posed by the COVID-19 pandemic. The design, manufacture, and inspection of radiant waste boilers and convective waste boilers require close integration and collaborative efforts among the fields of boilers and pressure vessels, as well as thermal energy and chemical engineering. To overcome these difficulties, Harbin Electric Boilers made full use of the advantages of its corporate structure, receiving strong support in terms of technology, production, management, and other aspects from its sister companies within the Harbin Electric Group. The senior leaders of Harbin Electric Boilers have planned ahead and adopted innovative approaches to ensure the steady and orderly progress of the project. In the face of the impact of the pandemic, the front-line workers at Harbin Electric Boilers showed selfless dedication and a willingness to make sacrifices; there are countless touching stories of this kind. Liu Binchao, the chief designer for internal components, received news that his father had suddenly fallen seriously ill while work was at a critical stage in terms of technology development. After entrusting his father to his family for care, he chose to remain at his post ； Wang Zhiying, the boiler technician, suffered sudden vocal cord damage; she returned to work just 3 days after the surgery to continue her duties ； Liu Yinhé and Luo Zhenyang, the nuclearization process engineers, have young children. Due to their long-term presence at the project site, their children wouldn’t even recognize them when they returned home... Ultimately, thanks to the unremitting efforts of the R&D team, the company was able to fulfill the contractual obligations related to the Shenghong Refining and Chemicals project. Adversities forge greatness; the more difficult the times, the more it highlights the unity and solidarity among the people of Harbin Boiler, as well as their spirit of striving to reach new heights.
As of June 5, 2023, the 2 2,000-ton class semi-coked gasifier units developed independently by Guizhou Aerospace Maiwei Technology Co., Ltd. have been operating continuously and stably for 100 days as part of the hydrogen production improvement and by-product ammonia generation upgrade project at Zhejiang Baling Hengyi Caprolactam Co., Ltd. It is understood that this project utilizes the powder gasification technology based on the Aerospace Maiwei semi-waste boiler process, replacing the normal-pressure fixed-bed batch gas generation process, in order to supply hydrogen steadily to downstream applications; simultaneously, synthetic ammonia is produced as a by-product for use in the caprolactam production facilities. To improve efficiency and reduce costs, Baling Hengyi actively explores coal blending methods, optimizing the combination of different coal types to minimize expenses. The technology team at Aerospace Maiwei, in collaboration with the workshop staff, assessed the reaction conditions inside the gasification furnace by examining parameters such as the temperature of the gasification chamber, the pressure difference at the slag outlet, the morphology of the coarse slag, and the methane content in the syngas. By adjusting the operating parameters in a timely manner, they ensured the stable operation of the gasification unit. It is reported that Aerospace Maiwei’s half-waste gasification technology transforms the traditional single \"gasification island\" into a new, green and efficient development model of \"gasification island + power island + environmental protection island\". Under various operating conditions, the radiant waste boiler consistently produces high-pressure steam at 9.8 MPa without any decline in performance, thereby solving the industry-related problem of ash and slag accumulation in the waste boiler section of gasifiers in such processes. The by-product steam generated by each gasifier in the Baling Hengyi project can generate approximately 80 million yuan in additional revenue for the enterprise each year. The MaWeiBan waste-heat gasification technology for the aerospace industry can also recover and utilize the high-grade thermal energy of high-temperature crude syngas. As a result, the temperature of the gas entering the quench chamber is significantly reduced, which leads to a reduction of the quenching water volume by about 50%. This in turn reduces the load on the slag-water system as well as the energy consumption of the facility. Since operations began on November 23, 2022, the actual carbon conversion rate at the Baling Hengyi project has exceeded 99%; the residual carbon content in the coarse slag is 1%–3%, while that in the fine ash is around 20%. Most of the ash contained in the syngas is separated in the cyclone separator, which reduces the risk of clogging due to ash in the syngas and within the system. This improves the stability of the facility and enhances the conditions in the gasification workshop. According to Tang Yanchao, the director of the hydrogen and ammonia production unit at Baling Hengyi, calculations based on the actual operational data on site show that the comprehensive energy consumption per ton of ammonia produced in this project is about 7% lower compared to the quenching process, resulting in a cost reduction of around 200 yuan per ton of ammonia – demonstrating significant economic benefits.
【Ten Years of Rapid Development in Chemical Processing Equipment】China’s first domestically developed tail-turning frame from 2013 to 2023 https://bbs.hcbbs.com/thread-4304744-1-1.html (Source: Haichuan Chemical Industry Forum)