New Century Chemical Machinery Advanced Manufacturing Technology (1)

Disciplinary Perspectives Advanced Manufacturing Technology for Chemical Machinery in the New Century (Tu Shandong 1 Wang Zhengdong 1 Gu Boqin 2 (1. School of Mechanical Engineering, East China University of Science and Technology, Shanghai 200237; 2. School of Mechanical and Power Engineering, Nanjing University of Technology, Nanjing, Jiangsu 210009) Arrow Technology and Nuclear The development of technology, more fundamentally, it affects the rapid development of many industries in the national economic construction, such as chemical industry, power generation, metallurgy, pharmaceuticals, etc. China's chemical machinery manufacturing industry is gradually growing with the continuous development of the process industry. As a result, it has so far formed a production and supply and sales channel throughout the country, a complete range of design and manufacturing systems, and an education and scientific research system composed of many universities and research institutes.

Chemical machinery originates from the chemical industry, and its application far exceeds the fields defined by traditional chemical industry. For decades, the chemical machinery industry has played a major role in providing equipment for domestic chemical production and construction. At the same time, equipment in the energy industry, metallurgical industry and other fields are mostly domestic chemical machinery products. According to statistics, the small and medium-sized chemical and power generation enterprises throughout the country are basically domestically sourced from China; and since the 1970s, a large number of large-scale production facilities have been established since the introduction of technical equipment from abroad, and a considerable amount of spare parts are now available. Accessories, Machinery and Equipment, Tu Shandong (1961-), Male, Professor, Ph.D., Ph.D., Changjiang Scholar, Distinguished Professor, Department of Chemical Process Engineering, East China University of Science and Technology, Wang Zhengdong (1950-), Male, Professor, Ph.D., Doctor; Gu Boqin ( 1957-), Male, Professor, Ph.D., PhD, Associate Dean, Nanjing Institute of Mechanical and Power Engineering.

table! China's chemical machinery technology development brief time content field, unit in the 1960s small and medium-sized chemical, power generation equipment, national chemical, power generation companies in the 1970s introduced foreign technology and equipment, construction of large-scale chemical plant built more than 10 sets of polyvinyl alcohol device , Design and equipment supply are based on the domestic nationwide annual 1985 large-scale urea plant localization: the successful development of urea synthesis towers, high pressure scrubbers, carbon dioxide compressors and other key large urea plant equipment, an annual output of 520,000 tons urea plant Localization rate of equipment reached over 80% Localization of Zhejiang Jinghai Petrochemical Plant, Urumqi Petrochemical Plant, Yinchuan Chemical Fertilizer Plant, etc. Coal carbide, calcium carbide, and acetylene chemical equipment: 45,000 tons of large-scale closed furnace, dry dust removal, and gas burning kiln The new technology was digested and absorbed by the organization. The domestic design and manufacturing equipment were all completed and put into production. The key equipment such as ammonia pelletizers for ammonium phosphate production was successfully developed in 1993, such as Taiyuan in Shanxi, Hebei Xiahua Garden, and Suihua. Heavy-duty bucket elevator, 10,000-ton phosphate storage tank rubber anti-corrosion lining, jet mixer, Venturi counter-blow bag filter And so on, the domestic production rate of 240,000 tons of ammonium phosphate production equipment reached 85%. There were 278 sets of equipment for the 200,000 tons of sulfuric acid plant. Successful development of boiling roasters, waste heat boilers, electrostatic precipitators and other key equipment, the localization rate reached 85%. Chemicals, Dahua, Guixi Fertilizer Plant, and Tongling Phosphoryl Ammonium Plant were successfully developed in 1990 with an annual output of 600,000 tons of alkali plant equipment: light ash calciner, heavy ash calciner, carbonization tower, alkali filter, large plate changer Key equipment such as heat exchangers, soda ash packaging machines, and CO2 compressors have reached the level of introducing advanced foreign equipment. Tangshan Soda Plant, Lianyungang Soda Plant, and Weifang Soda Plant Annually 1987 China's first oil production line with an annual output of 300,000 tons of synthetic ammonia Pilot project, stable production for a long period of time Shanghai Wujing Chemical Plant Co., Ltd. developed a 200,000 t/a synthetic ammonia plant with natural gas as raw material in 1992. The synthesis gas compressor was a steam turbine unit, a reform furnace tube, and a combined ammonia. The cold equipment, a waste heat boiler, steam superheater and other difficult equipment are in good operation. The main performance indicators have reached the international advanced level in the 1980s, and the ton of ammonia energy consumption is below 7 million kcal. The localization rate of the equipment reached 83%. Sichuan Chemical Plant's annual manufacturing capacity of ion-membrane electric cell in 1993: innovative development of a Chinese-style electrolytic cell.

In 1993, the first Chinese-style 10,000-ton ion-exchange membrane electrolyzer was successfully put into operation. Its indicators were comparable to international standards. The synthetic ammonia complete sets of equipment using coal as raw materials were developed at the Quzhou Chemical Plant. Domestically, it was possible to purchase only foreign patents. Completion of design and provision of some key equipment Lunan Fertilizer Plant Annual 800,000 t/a hydrocracking unit: 400t/a and 560t/a hydrogenation reactor, thread locking ring high pressure heat exchanger, circulating hydrogen compressor, new Hydrogen compressors and other key equipment are developed by the domestic, localization rate of 90% Zhenhai Refining & Chemical Co., Ltd. annual 140,000 9/a high-density polyethylene device localization rate of 80% or more, including the mirror polished inner wall reactor, large-scale Centrifuges, large-scale rotary dryers and other equipment have been developed by domestic Yanshan Petrochemical Company's centrifugal compressors of the 300,000 9/a large-scale synthetic ammonia and 520,000 9/a urea plants of the year 1994. They have designed and manufactured natural gas compressors and ammonia. Sichuan Refrigerated Compressor Unit and C2 Compressor Unit Sichuan Tianhua Co., Ltd. Annual Output of 450,000 Tons of Ethylene Reformed and Expanded Successfully, Localization Rate of 70% Domestically Designed 69,000/a and 89,000/a Ethylene Cracking Furnaces CBLI, CBL IV furnace approaching country Advanced level. Key equipment such as cracking gas compressors, propylene compressors, and polypropylene plant loop reactors achieved localization Yanshan Petrochemical Company Liaoyang Chemical Fiber Corporation Daqing Petrochemical, Maoming Petrochemical, Dalian Petrochemical, etc. Year 1999 Invented a large-scale coal chemical complete equipment: Based on the Lanzhou Gas Project (localization rate of 40%) and Harbin Gas Project (localization rate of 60%), the local gasification rate of urban gas equipment in Yima Gas Project of Henan Province reached more than 80%, reaching the international advanced level in the early 1990s. The level of equipment technology for pressurized water reactor nuclear power plants in Lanzhou, Harbin, and Henan Yima, and the localization rate of nuclear power equipment have reached more than 50%, and 85% of Chashma nuclear power plant equipment is manufactured in China. Key equipment such as reactor pressure vessels, reactor internals, and steam generators have been successfully applied to the nuclear power plants in Guangdong Daya Bay, Qinshan, Chashma, Pakistan, Tianwan, Jiangsu, and Lingdong, Guangdong, etc., to achieve localization of 109,000/a polyester complete sets of equipment. Yizheng Chemical Fiber Company and even key equipment were replaced by domestic products. enter! In the post-1990s, in order to adapt to the scale of process industry production and the trend of increasingly large-scale equipment, the state has attached great importance to the localization of large-scale complete sets of equipment. After more than a decade of efforts, a large number of large-scale production equipment that can represent the current world level can basically Based on domestic manufacturing. The brief history of the development of China's chemical machinery technology is shown in the table.

Scientific research and discipline construction of chemical machinery are important guarantees for technological innovation of enterprises. The healthy development of chemical and other process industries in China is inseparable from the research of chemical process machinery disciplines. Over the past 40 years of hard work, the scientific research of chemical machinery has made important progress in many aspects: The theory and assessment of structural integrity of pressure vessels and pipelines have yielded fruitful results: China's pressure vessel safety assessment technology from the 20th century The research began in the 1970s, and after more than a decade of hard work, the 1984 directive on pressure vessel defect assessment (CVDA-84) was issued. Practice has proved that CVDA-84 is a safe engineering method that has played an important role in the safety and security of industrial equipment in China and has achieved great social and economic benefits. During the "Eighth Five-Year Plan" period, the State Science and Technology Commission issued a technical research project, organized 46 units, and more than 260 scientific and technical personnel. After five years of hard work, it has achieved fruitful results, making China's pressure vessel safety assessment theory and technology close. The level of developed countries. During the "Ninth Five-Year Plan" period, on the one hand, it has promoted and applied the results already achieved; on the other hand, as the focus of national research, it has turned to the safety assessment technology of the existing industrial pressure pipeline. At the same time, under the support of the National Natural Science Foundation of China, chemical static equipment accident prediction technology has achieved great development both theoretically and practically. Uncertain factors in safety assessment and life prediction have been fully taken into account, and not only accidents can be predicted. Whether it occurs, it can predict the probability and severity of occurrence. Long-term scientific research has effectively suppressed the explosion accidents of China's boiler pressure vessels and ensured the healthy development of the process industry.

The state monitoring technology of moving equipment has been well developed. For example, the on-line state monitoring and distribution monitoring technology of the unit is an innovative development in China. The key and important machines and pumps are monitored by the sensor group, and the fiber optic information highway will monitor the diagnostic center. Distributed monitoring system is connected with all other online monitoring systems to form a local area network for monitoring the entire enterprise. It is especially suitable for the monitoring of machine and pump groups in process industrial enterprises.

The redesign principle of high-temperature component life extension has been successfully applied in industrial production: The design of high-temperature structures are generally based on 100,000 hours of allowable strength data, but the actual life is generally higher than the design life, how to approach the high temperature of the design life The redesign of equipment to tap the potential of expensive equipment is a highly challenging problem. The Chinese scholars have developed multi-disciplinary knowledge of fracture mechanics, materials science, and computer technology to develop high-temperature structural vulnerability identification technologies. Through the study of damage theory and high-temperature fracture theory, the principle of high-temperature structural redesign has been developed to enable the maintenance of high-temperature equipment. Can be more accurate positioning and timing.

The design theory and manufacturing technology of flat-wound pressure vessels are the first achievements of scholars and engineering technicians in China: After more than 30 years of theoretical analysis and experimental research, and a large number of industrial applications, it has been proved that the container has low manufacturing cost, safety and reliability, Only leakage does not explode and other advantages. After strict review by peer experts, the container has been listed in ASME Boiler and Pressure Vessel Code cases since 1996.

Heat pipe heat exchanger design theory and technology: The industrial application research of domestic heat pipe technology began in the mid-1970s. After laboratory exploration and research, in 1970-1981, two kinds of heat-exchange equipments, the heat pipe air preheater and the heat pipe waste heat boiler, were successfully studied, and the technical incompatibility of carbon steel and water was solved. Industrial applications paved the way. From 1980 to 1995, after fifteen years of industrial application practice, under the efforts of national heat pipe science and technology workers, the heat pipe technology has been increasingly perfected, the application surface has been gradually expanded, and the benefits have been significant. It is estimated that the amount of coal saved by heat pipe heat exchangers Has reached more than 20,000 tons. During the "Ninth Five-Year Plan" period, the alkali high-temperature heat pipe was well developed, which solved the problem of purification of liquid metal at high temperatures, high temperature heat pipe materials and manufacturing problems, and high-temperature heat pipe gas-gas heat exchangers have been put into practical industrial applications.

Hypergravity Mass Transfer Theory and Equipment Technology: National Science and Technology Commission in Exhibition. The ultra-gravity reaction precipitation method for the synthesis of nanomaterials was created, and the world's first production line for nano-calcium carbonate production by the hypergravity method was built. The oil field water injection and deoxygenation super-gravity demonstration device has been successfully operated in Shengli Oilfield; the seawater deoxygenation gravity device has been Application on the offshore oil platform; The deoxygenation device of the boiler water dehydration method of the high-gravity method was also successfully put into operation in the oil field.

The vibration field enhanced polymer plastic injection molding technology has been rapidly developed. For example, the new technology of dynamic electromagnetic polymer molding has been successfully applied: Chinese scholars invented the electromagnetic dynamic plasticizing extruder and introduced the vibration force field to the polymer plastic for the first time. The entire process of extrusion. This new type of dynamic molding equipment has the following advantages: 70% volume reduction, 50% reduction in manufacturing costs, 40% to 50% reduction in energy consumption, significantly reduced extrusion swell, and high product quality.

These achievements are an important symbol for China's polymer molding processing equipment to reach the international advanced level.

Efficient separation equipment technology: As polymer materials and ceramic materials are used in the preparation of separation membranes, membrane separation equipment technology has been successfully applied in many fields, widely used in chemical, food, medicine, energy, molten metal filtration, powder transportation, Environmental protection, sewage treatment, radioactive waste treatment, etc. The realization of many high-tech processes is related to its application, such as the development of small-scale desalination equipment for pervaporation. This method is based on the swelling property of a hydrophilic dense membrane in water, enabling seawater to enter and pass through the cross-linked network of a polymer membrane in a molecular state, thereby obtaining high-purity fresh water. The system is mainly composed of salt water heating system, membrane separation module, fresh water condensate collector and vacuum system. It can separate seawater with 3% salt content into high purity water. Because ceramic membranes have the advantages of corrosion resistance, high temperature resistance, and reusability, the state attaches great importance to its basic and industrial research. The National Natural Science Foundation of China and the 863 Program have successively supported research in this field, and have been acquired in industrial practice in recent years. A great success, such as in the banknote printing wastewater treatment, industrial waste lye recovery, sulfuric acid titanium dioxide wastewater treatment, wastewater high temperature ultrafiltration recovery and other fields have been put into use.

The progress in efficient cyclone separation equipment technology is also remarkable. The successful development of the PV type high efficiency cyclone separator at the end of the 1980s was applied to the technological transformation of the catalytic cracking unit, which reduced the cost of the expensive catalyst unit, and brought huge economic benefits to the national oil refining companies. The ET type and E-type high efficiency cyclone separators are used in catalyst recovery, high temperature dust removal, exhaust gas purification and other occasions to create significant social and economic benefits.

Progress in other areas, such as high-pressure and ultra-high pressure vessel technology, enhanced heat transfer technology, heat pump technology, high-efficiency packing and tower equipment technology, etc., are limited in length and will not be discussed one by one. These scientific and technological achievements have supported China's socialist construction in many ways. First, it has ensured the efficient, safe and reliable operation of large-scale process industrial installations. Second, in the process of reform and opening up, it has provided new unit equipment technologies and supported chemical machinery. The structural adjustment of the manufacturing industry. Third, it provided advanced equipment for the high-tech technological process and accelerated the industrialization of high-tech industries in China. It also promoted the discipline construction of chemical process machinery, and high-level scientific research enriched the connotation of the discipline. At the same time, it also expanded the extension of disciplines and made high-level talent come to the fore.

In the early years after the founding of the People's Republic of China, the system of industrial economy in China urgently needed to be established, and engineers and technicians in chemical process machinery were urgently needed. In 1952, the discipline of chemical machinery was set up in universities and colleges. After more than forty years of hard work, educators in China’s chemical industry, machinery, and materials fields, while learning about the establishment of former Soviet subjects according to their national conditions, have dissolved into unit operations proposed by the United States and further strengthened the content of materials disciplines. Created a discipline framework of chemical process machinery with Chinese characteristics. With the increasing demand for intelligentization of chemical installations, control knowledge and information technology have been given corresponding emphasis. In order to further adapt to the market economy's demand for talents, at present, undergraduate professional titles have been changed to “process equipment and control engineering”. The discipline of chemical process mechanics has become increasingly important in China's national economic construction, and there has been no reduction in talent demand. Therefore, this discipline has a strong vitality under the complicated market economy conditions.

Chemical machinery technology education has a relatively wide coverage, and personnel training specifications include bachelors, masters, and doctorates, as well as secondary school, college, adult continuing education. At present, there are 58 colleges and universities in the country that have set up a "process equipment and control engineering" undergraduate majors, undergraduate majors belong to the mechanical engineering category, and graduate students majors belong to power engineering and engineering thermal physics. Since chemical process machinery is a highly intensive and highly integrated technical discipline, it is still worthwhile to study whether universities and postgraduate education should focus on that aspect, cover those contents, and how to adopt advanced educational methods.

As mankind moves toward the 21st century, the resources of the earth become increasingly tense, and the quality of the environment is declining. At the same time, the production and application of knowledge and information will become the main form of creating wealth in the new century. Therefore, the design, manufacture and operation of chemical process machinery have been proposed. The higher the demand, the science of process equipment is facing the severe challenges of knowledge economy, information, environment and resources.

This is manifested first in the pressure from the international community: (1) China has already joined the WTO, producing and manufacturing products with independent intellectual property rights and improving the international competitiveness of China's process equipment manufacturers. It is very urgent. Through long-term efforts, the chemical machinery manufacturing industry has made great progress in contracting the design and manufacture of large-scale chemical equipment with contemporary international standards. However, the construction of large-scale chemical production facilities has failed to achieve domestic technology. At the same time, the domestic high-tech chemical equipment market is still occupied by foreign companies, and these large-scale, modern, high-tech production facilities and high-tech chemical and material production facilities are the backbones of domestic industrial production today and in the future. These devices have advanced product yields, energy consumption, and environmental protection indicators, and they have a more promising role in technological development. Therefore, in the long run, if we do not rapidly increase the ability to design innovation, adopt advanced manufacturing technologies, and occupy large-scale, high-tech chemical equipment markets, the existing chemical equipment market will also be difficult to keep.

(2) In order to make China's process industry (chemical, petrochemical, power generation, metallurgy, food, pharmaceuticals, etc.) competitive, it is also necessary to ensure the efficient operation of equipment and reduce production costs. Most of the process industrial installations are large-scale continuous production, and they will lose hundreds of thousands of yuan or even several million yuan in one day of production suspension. The developed countries have already completed a three-year or even longer overhaul period, and most of them still stay at the level of two years of repairs. Therefore, the research of process equipment must ensure the long-term efficient operation of the equipment to the greatest extent possible. On the one hand, the equipment should be redesigned according to the latest scientific methods. On the other hand, the advanced manufacturing process should be used to remanufacture the equipment and fully tap the equipment. The potential to extend equipment life and at the same time safeguard the safe operation of the equipment.

Secondly, the challenges brought about by the complexity of chemical process equipment itself. In order to realize different physical and chemical reactions, the technological process is often ever-changing. Therefore, the process equipment is highly process-friendly; along with new energy sources, new materials, life sciences, and the environment The emergence of numerous new processes such as protection requires more perfect cooperation between process equipment and processes.

In order to improve the efficiency of the process industry, process equipment tends to be serialized, and the scale of the equipment tends to be large. At the same time, long-period and long-life operation are required, and high requirements are placed on the safety and reliability of the process equipment.

(Furthermore, the service conditions of process devices vary widely, with high temperature, low temperature, and deep cold; there are ultra-high pressure, high pressure, medium, low pressure, vacuum, etc.; there are differences in vapor-liquid-solid three phases; there is strong acid, strong alkali, highly toxic, Inflammable, explosive, etc. These process characteristics determine the complexity of the process-equipment related knowledge system, which also leads to a long product development cycle and low design efficiency, but due to the adoption of information technology in the domestic chemical machinery manufacturing industry. Far behind the similar foreign manufacturing enterprises, the acquisition of product innovation knowledge and the ability to operate the relevant knowledge are very low, so the problem of the lack of innovation capacity in the domestic chemical machinery manufacturing industry is particularly serious.(continuation) 20th century China's chemical industry Mechanical Technology The glorious achievements of mankind in the 20th century can generally be summarized by the following words: a technology: computer technology; two theories: relativity theory and quantum theory; three projects: Manhattan (Atom Bomb) project, Apollo moon landing Engineering, Human Genetic Engineering; Four Models: Quark Model, Big Bang Model, DA Double Helix Model, Earth Block structure model: Mechanical engineering technology has an important supporting role for all these achievements, and it can be said that without mechanical engineering technology, all these achievements cannot be achieved.The support of the above-mentioned achievements by chemical machinery technology is also decisive. The processing aspects, such as the development of electronic chemicals, the processing of chip materials, the manufacture of shell materials, the formation and maintenance of ultra-clean environments, etc., are all due to the chemical machinery technology.The production of nuclear materials in Manhattan, Apolloden The production of rocket propellants and spacecraft thermal control technologies in the Moon Project are no exceptions.

2 For China, chemical machinery technology not only supports the fire