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Gas compressors Commonly used gas compressors in petrochemical production plants are centrifugal gas compressors and reciprocating gas compressors. Over the years, China’s compressor manufacturing industry has overcome many difficulties and made major breakthroughs on the basis of the introduction of foreign technology, digestion and absorption, and independent development. For example, the main fan and rich gas compressors used in catalytic cracking units, circulating hydrogen compressors for hydrogenation plants, new hydrogen compressors, three ethylene compressors, and four major chemical compressor units have been used in petrochemical production. Among them, the horizontal split centrifugal compressor and axial compressor manufacturing technology has approached or reached the international advanced level of similar products, reciprocating piston compressors reach the level of similar products in the world.
At present, the international development direction of centrifugal compressors is the continuous increase of compressor capacity, new type of gas seals, magnetic bearings and non-lubricated couplings; high-pressure and small-flow compressors are emerging; and the theoretical research of ternary flow is further deepened. Not only applied to the design of the impeller, but also to the design of stationary components of the vane diffuser, the unit efficiency has been improved; noise protection technology has been adopted to improve the operating environment.
There are more than a dozen domestic manufacturers of compressors for petrochemical companies, mainly Shenyang Blower Co., Ltd., Shaanxi Blower (Group) Co., Ltd., and Shanghai Blower Works, among which the centrifugal compressor produced by Shenyang Blower Co., Ltd. is in China. Petrochemical compressor market share reached more than 50%. At present, China's rich gas compressors have an import flow of 81600 Nm3/h and a power of 7166 KW. They have been used in 3 million tons/year of catalytic cracking and delayed coking devices; centrifugal circulating hydrogen compressors have a flow rate of 250,000 Nm3/h and power of 1600 KW. With a pressure of 18Mppa, it has been used in 1.2 million tons/year of hydrocracking unit; cracking gas compressor flow rate reaches 120,000Nm3/h, power reaches 18000KW, has been applied to 30.5 million tons/year ethylene cracker; air compressor of large fertilizer plant , Natural gas compressors, ammonia compressors, and carbon dioxide compressors have been used in 20.3 million tons of synthetic ammonia plants; the air compressors of the air separation plants have reached 220000Nm3/h of air compressors, and their power has reached 17580KW. They have been used in 40000Nm3/h air separation plants. Shaanxi Blower (Group) Co., Ltd. has successfully designed and manufactured more than 170 sets of axial compressors with excellent performance on the basis of the introduction of Swiss Sulzer Technology. Among them, more than 60 sets of main and auxiliary fans for catalytic cracking units. The main fan manufactured for the Dalian Petrochemical Company's 3.5 million tons/year catalytic cracking unit is currently the largest axial compressor in domestic petrochemical plants, with a flow rate of 300,000 Nm3/h and a power of 40000 KW.
However, China's centrifugal compressors are still unable to meet domestic needs in terms of high technology, high parameters, high quality, and special products, and about 50% of products need to be imported. In addition, there are still gaps in the level of technology, quality, and completeness. With the continuous expansion of the scale of petrochemical production, China's centrifugal compressors will face new challenges in terms of scale.
The development direction of foreign reciprocating piston compressors is large capacity, high pressure, compact structure, low energy consumption, low noise, high efficiency, good plasticity, strong exhaust gas purification ability; Significant savings in installation, basic and commissioning costs; Continuous development of new valve operating under variable conditions to greatly increase valve life. In product design, application of compressor thermodynamics, dynamics calculation software and compressor operation process simulation Software, etc., to improve the accuracy of the calculation, through the comprehensive simulation model to predict the performance of the compressor under the actual operating conditions in order to improve the success rate of new product development, the mechanical and electrical integration of the compressor has been strengthened. Using computer automatic control, automatic display of various operating parameters, optimization of energy-saving operation status, optimization of online operation, abnormal display of operating parameters, alarm and protection; product design emphasis on industrial design and environmental protection, compressor appearance more in line with environmental protection requirements, etc. .
After 20 years of development, China has already formed hundreds of products of dozens of compressor series such as L, D, DZZ, H and M types. At present, the domestic small and medium-sized compressors have basically met the needs of the domestic petrochemical industry, but large-scale reciprocating compressors can not meet the needs. Shenyang Gas Compressor Co., Ltd. has introduced a complete set of reciprocating compressor design and manufacturing technology from Germany, and has made breakthroughs in the development of large and medium reciprocating compressor technology. In 1990, China successfully developed 4M50 large-scale hydrogen reciprocating compressors that meet the current international standards. In 1996, it introduced 6M50 series of nitrogen-hydrogen compressors. In 1998, it successfully developed 4M80 series of large-scale hydrogen compressors. The volumetric flow of the reciprocating new hydrogen compressor reaches 34000Nm3/h, the piston pressure reaches 80KN, the outlet pressure reaches 19Mpa, and the power reaches 4000KW. It has been used for 2 million tons/year of residue hydrodesulfurization equipment. The flow rate of the labyrinth compressor designed and manufactured in China has reached 980 Nm3/h, the outlet pressure has reached 3.8 Mpq, and the used 70,000 tons/year polypropylene plant has been used.
Compared with the technical level of foreign reciprocating compressors, China's main gap is poor basic research, low product technology development capabilities, and technological equipment and experimental methods, the product technology starting point is low, specifications, efficiency, manufacturing quality, poor reliability. In addition, products with high technological content and special requirements cannot meet domestic demand.
Petrochemical special pumps International petrochemical pump manufacturers mainly include Swiss Sulzer Company, Japan Ebara Corporation, German KSB Company, and US Goss. The development direction of petrochemical pumps is large-scale, high-speed, electromechanical integration, completeness, standardization, serialization and generalization of pump products; wide variety of products, wide performance, long life, and high reliability; large-scale pump seals and bearing production Specialization and specialization; especially high-temperature, low-temperature and ultra-low-temperature pumps, high-speed pumps, precision metering pumps, anti-corrosion pumps, the transmission of viscous media and pumps with solid particulate media, and shielded pump technology has developed rapidly.
Compared with foreign countries, China's petrochemical pumps are lagging behind in terms of design theory and design methods. Product development uses more methods of imitation and analogy, lacks theoretical basis and experimental research data; processing equipment and technology are relatively backward, and machining accuracy is low. The production efficiency is low; the degree of product serialization and generalization is not high, and the specification variety is small; there is still a big gap between pump efficiency, quality and reliability, sealing performance, and corrosion resistance. At present, China's petrochemical pumps still have a lot of dependence on imports.
China's petrochemical general machinery status quo and future development trend analysis
Petrochemical general machinery includes gas compressors, petrochemical special pumps and valves.