甲醇合成反应器制造工艺研究
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摘要
压力容器几乎是所有工业生产、科学研究和人民生活中广泛使用的一种承压设备。压力容器的制造是关系国民经济发展的重要领域,其应用范围和重要性正日益扩大和增长。压力容器制造技术涉及到冶金、机械加工、焊接、腐蚀与防腐、无损检测、安全防护等众多行业,因此制造过程要求多行业、多学科、多方面的协作共同来完成。
甲醇合成反应器是煤化工装置中最重要的设备之一。由于甲醇合成反应器结构复杂,制造难度大,其中关键部件制造技术如筒体成形技术研究、管板堆焊防变形措施研究、产品总装工艺技术研究和检验技术氨渗漏试验几乎涉及压力容器制造过程中的大部分关键制造工艺,研究总结甲醇合成反应器的制造工艺,对我国煤化工领域有着重要意义。
本文制定了单节筒体成形方案及管板堆焊防变形措施研究,采取一定的工艺措施,提出了以防为主的解决方案；甲醇合成反应器的总装工艺的研究过程中,确定了总装的最后一条环缝,装焊成两大段后再装隔板,调整两大段旋向位置,保证同轴,并注意到穿管需要特定的穿管顺序,研究整体总装工艺顺序后,使得产品总装顺利进行；氨渗漏试验是检验容器是否连接有效的较严格的手段之一,提出了氨渗漏试验工艺守则和解决问题的方案,使氨渗漏试验得以实施。
通过甲醇合成反应器的成功制造,验证了我们在制造过程中提出的方案的是可行的,并取得了良好的效果。甲醇合成反应器制造成功为我厂在今后制造大型的高精度管壳式换热反应器积累了宝贵的经验；也标志着我国大型高精度设备制造国产化水平又上了一个新的台阶。
Pressure vessels are pressure-retaining equipments which are widely used in almost all the areas of industry production、scientific research and human life.The production of pressure vessels play a great role in the national economy, Its application and importance increase by days.The manufacture technology of pressure vessels involve the areas of metallurgy、mechanical manufacture、welding、corrosion and corrosion protection、non destructive testing、safety protection and so on.So it needs the cooperation of different area、different subject、different aspect to work together.
The methanol synthesis reactor is one of the most important equipment in the coal chemical industry.With a complex structure,it is difficult to manufacture,almost all the key manufacture technology of the pressure vessels is involved here, for example:ylinder fabrication,the precaution of deformation when using overlay welding on the tube-sheet, final assembly and ammonia leakage test.Making studies on the manufacture technology have great means in the coal chemical industry.
In the paper we set down the single cylinder fabrication plan and the precaution of deformation when using overlay welding on the tube-sheet, it was through certain technical methods mainly by precaution. Talking about the final assembly, we determine the last circular seam, assemble the support plates after the equipment has being two big parts, adjust the position of two parts to make sure coaxial, and we also pay attention to the sequence of tube-inserting. All of these measures ensure the final assembly can smoothly go. The ammonia leakage test is a strict way to check the vessels.We set down the process specification and solution plan.
The successful manufacture of the methanol synthesis reactor prove that our plan is feasible and works well. It also accumulate valuable experience for our company when we manufacture such big and high precision shell-and-tube heat exchangers.And the localization of big and high precision equipments manufacture in our country improve on a new level.
甲醇合成反应器是煤化工装置中最重要的设备之一。由于甲醇合成反应器结构复杂,制造难度大,其中关键部件制造技术如筒体成形技术研究、管板堆焊防变形措施研究、产品总装工艺技术研究和检验技术氨渗漏试验几乎涉及压力容器制造过程中的大部分关键制造工艺,研究总结甲醇合成反应器的制造工艺,对我国煤化工领域有着重要意义。
本文制定了单节筒体成形方案及管板堆焊防变形措施研究,采取一定的工艺措施,提出了以防为主的解决方案；甲醇合成反应器的总装工艺的研究过程中,确定了总装的最后一条环缝,装焊成两大段后再装隔板,调整两大段旋向位置,保证同轴,并注意到穿管需要特定的穿管顺序,研究整体总装工艺顺序后,使得产品总装顺利进行；氨渗漏试验是检验容器是否连接有效的较严格的手段之一,提出了氨渗漏试验工艺守则和解决问题的方案,使氨渗漏试验得以实施。
通过甲醇合成反应器的成功制造,验证了我们在制造过程中提出的方案的是可行的,并取得了良好的效果。甲醇合成反应器制造成功为我厂在今后制造大型的高精度管壳式换热反应器积累了宝贵的经验；也标志着我国大型高精度设备制造国产化水平又上了一个新的台阶。
Pressure vessels are pressure-retaining equipments which are widely used in almost all the areas of industry production、scientific research and human life.The production of pressure vessels play a great role in the national economy, Its application and importance increase by days.The manufacture technology of pressure vessels involve the areas of metallurgy、mechanical manufacture、welding、corrosion and corrosion protection、non destructive testing、safety protection and so on.So it needs the cooperation of different area、different subject、different aspect to work together.
The methanol synthesis reactor is one of the most important equipment in the coal chemical industry.With a complex structure,it is difficult to manufacture,almost all the key manufacture technology of the pressure vessels is involved here, for example:ylinder fabrication,the precaution of deformation when using overlay welding on the tube-sheet, final assembly and ammonia leakage test.Making studies on the manufacture technology have great means in the coal chemical industry.
In the paper we set down the single cylinder fabrication plan and the precaution of deformation when using overlay welding on the tube-sheet, it was through certain technical methods mainly by precaution. Talking about the final assembly, we determine the last circular seam, assemble the support plates after the equipment has being two big parts, adjust the position of two parts to make sure coaxial, and we also pay attention to the sequence of tube-inserting. All of these measures ensure the final assembly can smoothly go. The ammonia leakage test is a strict way to check the vessels.We set down the process specification and solution plan.
The successful manufacture of the methanol synthesis reactor prove that our plan is feasible and works well. It also accumulate valuable experience for our company when we manufacture such big and high precision shell-and-tube heat exchangers.And the localization of big and high precision equipments manufacture in our country improve on a new level.
引文
[1]杨松.锅炉压力容器焊接技术培训教材.机械工业出版社,2006,17(4)：15-22
[2]赵建军,薛利平.甲醇生产工艺.化学工业出版社,2008,1-9,138-149
[3]张子锋,张凡军.甲醇生产技术.化学工业出版社,2008,1-6,109-110,126-149
[4]许祥静,刘军.煤炭气化工艺.化学工业出版社,2005,20-22
[5]付长亮,张爱民.现代煤化工生产技术.化学工业出版社,2009,103-107
[6]王志斌,压力容器结构与制造,化学工业出版社,2009,25-28
[7]陈裕川,钢制压力容器,机械工业出版社,2007,53-57
[8]刘湘秋,常用压力容器手册,机械工业出版社,2004,65-67
[9]宋崇民,李玉军,锅炉压力容器无损检测,黄河水利出版社,2002,113-116
[10]侯锡瑞,电站锅炉压力容器压力管道安全技术,中国电力出版社,2005,111-114
[11]邢晓林,化工设备,化学工业出版社,2005,119-124
[12]王非,林英,化工设备用钢,化学工业出版社,2004,156-159
[13]卓震,化工容器及设备,中国石化出版社,2008,212-214
[14]邵泽波,化工机械及设备,化学工业出版社,2007,222-227
[15]赵勇,50万t/a甲醇项目合成反应器设计与工业应用,煤化工,2008,137(4),6-11
[16]石玉千,李涛,应卫勇,房鼎业,大型甲醇合成反应器工况的数值分析,高校化学工程学报,2006,20(3),489-493
[17]张明辉,大型甲醇技术发展现状评述,化学工业,25(10),8-12
[18]汪家铭,低温甲醇洗净化工艺技术进展及应用概况,化肥工业,35(4),11-15
[19]付郁峰,大型甲醇合成反应器的制造,化学工业与工程技术,2008,29(3),41-44
[20]袁承春,韩君,杨兰,Φ3600mm甲醇合成反应器的研制,锅炉制造, 2004,22-24
[21]吴永兰,低压恒温甲醇合成系统的设计及应用,化肥设计,2007,45(3),27-29
[22]应卫勇,张海涛,马宏方,房鼎业,管壳外冷-绝热复合式甲醇合成反应器的应用,化工进展,2009,28,419-422
[23]徐兆瑜,甲醇产业的发展和工艺技术新进展,化工技术与开发,2008,37(10),20-26
[24]张殿奎,大型煤气化合成甲醇制丙烯(MTP)是我国煤化工的发展趋势,化工技术经济,2007,25(1),1-4
[25]胡益之,韩冬青,甲醇潜在市场分析,煤化工,2006,34(3),4-5
[26]张刚,王儒,30万t/a甲醇装置技术特点分析,河南化工,2006,23(12)：31-32
[27]李福达,杨志敏,城市煤气联产甲醇设备,河南化工,2007,24(2)：38-39
[28]张学镭,王松岭,陈海平等,焦炉煤气利用项目的经济性评价,现代化工,2006,26(1),47-50
[29]董秀勤.甲醇生产工艺技术简介.内蒙古石油化工,2007(07),38-40
[30]张飞,姜健准,张明森,甲醇制低碳烯烃催化剂的制备与进展,石油化工,2006,35(10),919-923
[31]汪家铭,日本MFR新型甲醇合成塔,四川化工,2006,9(1)：54-55
[32]范济民,杨旺,申峻,合成气的工业应用与催化剂研究进展,煤化工,2006,34(4)：14-17
[33]高晋生,张德祥,甲醇制低碳烯烃的原理和技术进展,煤化工,2006,34(4),7-13
[34]粱淑萍,浅谈甲醇下游产品的发展前景,纯碱工业,2000,(3),46-48
[35]张建国,宋昭峥,丁宏霞,增产丙烯的技术进展与我国发展对策,现代化工,2006,26(增2),5-9
[36]《现代化工》编辑部,甲醇制烯烃工艺与烯烃裂解工艺一体化示范装置,现代化工,2006,26(5),70
[37]《化工中间体》编辑部,煤化工成为世界经济热点,化工中间体,2006(12),401
[38]易丽丽,江海光,唐浩东,甲醇的应用及下游产品开发研究评述,浙江化工,2003,34(12),26-28
[39]薛彩霞,陈玉涌,甲醇工业发展方向及应用,应用化工,2006,35(5),382-384
[40]肖海成,甲醇合成反应器概述,云南化工,2002,8(4),11-13
[41]刘鸿生,朱德林,国内外主要低压甲醇合成塔特性简介,甲醛与甲醇,2003,(2),32-33
[42]Mahajan A, Kirwan D J Micromixing effects in a two impining jets precipitator A IChEJ,1996,42(7):1801-1814.
[43]Cornthwaite, Derek(Chicago,IL), Methanol synthesis catalyst, US:36-39
[44]Short, Glyn D(Cleveland, GB), Jennings, James R.(Cleveland, GB), Catalytic process, US:513-516.
[45]Strel S. Mega-methanol and what to use it for, Nitrogen Se & Methanol, 2001,254(6),23-30.
[46]Keil F J. Methanol to hydrocarbons, process technology, Microporous and Mesoporous Materials,1999,29(1-2),49-66.
[47]Grimm P. Six years successful operation of Linde is other mal reactor, Linde Reports on Science and Technology,1991, (49):57-59.
[48]Burch R, Golunski S E, SpencerM S. J Chem Soc, Faraday Trans,1990, 86(15),2-8
[49]Denshchikov V A, Kont ratev, VN, Romashov A N Interaction between two opposed jets Fluid Dynamics,1978,6:924-926
[50]Bagdasarin A J, Bereczky E L, Ishiguro Tet all Investigation of 26 Year Old Hydroprocessing Reactors, A Summary Report The NACE Annual Conference and Corrosion Show.Paper No119-123
[51]Baker K,Sloan J R,Upitis E.Repair of a 21/4Cr-1Mo Petrochemical Reactor.WRC Bulletin,412,1996.
[52]Autor.China leads world in methanol fuel blending. Hydrocarbon Processing March,2008(5),19
[53]Petrochemical handbook methanol. Hydrocarbon Processing,1993(5),190
[54]Sunggyu Lee,Abhay Sardesai Liquid phase met hanol and dimethy her synthesis from syngasl Topics in Catalysis,2005,32:197-207
[55]Jot himurugesan K, J ames G Goodwin J Development of Fischer Tropsch catalyst s for slurry bubble column reactors Catalysis Today,2000,58: 335-344
[56]Giuseppe Biardi, Giancarlo Baldil Three2 phase catalytic reactorsl Catal ysis Today,1999,52:223-234
[57]Krishna R, Sie S T Design and scale up of the Fischer Tropsch bubble column slurry reactor Fuel Processing Technology,2000,64:73-105
[58]Art hur H Lefebvrel Atomization and Spraysl New York:Hemisphere Publishing Corporation,1987:217
[59]Jianhua Wang, Rayford G Ant hony, Aydin AkgermanlMat hematical simulations of t he performance of t rickle bedand slurry reactors for met hanol synt hesisl Computers and Chemical Engineering,2005 29:2472-2484
[60]Vijayaraghavan P, Conrad J Kulik, Sunggyu Leel Masst ransfer comparison between mechanically agitated slurryreactor and liquid ent rained reactor in the met hanol synt hesisprocessl Fuel Science and Technology,1992, 3:1577-1578
[2]赵建军,薛利平.甲醇生产工艺.化学工业出版社,2008,1-9,138-149
[3]张子锋,张凡军.甲醇生产技术.化学工业出版社,2008,1-6,109-110,126-149
[4]许祥静,刘军.煤炭气化工艺.化学工业出版社,2005,20-22
[5]付长亮,张爱民.现代煤化工生产技术.化学工业出版社,2009,103-107
[6]王志斌,压力容器结构与制造,化学工业出版社,2009,25-28
[7]陈裕川,钢制压力容器,机械工业出版社,2007,53-57
[8]刘湘秋,常用压力容器手册,机械工业出版社,2004,65-67
[9]宋崇民,李玉军,锅炉压力容器无损检测,黄河水利出版社,2002,113-116
[10]侯锡瑞,电站锅炉压力容器压力管道安全技术,中国电力出版社,2005,111-114
[11]邢晓林,化工设备,化学工业出版社,2005,119-124
[12]王非,林英,化工设备用钢,化学工业出版社,2004,156-159
[13]卓震,化工容器及设备,中国石化出版社,2008,212-214
[14]邵泽波,化工机械及设备,化学工业出版社,2007,222-227
[15]赵勇,50万t/a甲醇项目合成反应器设计与工业应用,煤化工,2008,137(4),6-11
[16]石玉千,李涛,应卫勇,房鼎业,大型甲醇合成反应器工况的数值分析,高校化学工程学报,2006,20(3),489-493
[17]张明辉,大型甲醇技术发展现状评述,化学工业,25(10),8-12
[18]汪家铭,低温甲醇洗净化工艺技术进展及应用概况,化肥工业,35(4),11-15
[19]付郁峰,大型甲醇合成反应器的制造,化学工业与工程技术,2008,29(3),41-44
[20]袁承春,韩君,杨兰,Φ3600mm甲醇合成反应器的研制,锅炉制造, 2004,22-24
[21]吴永兰,低压恒温甲醇合成系统的设计及应用,化肥设计,2007,45(3),27-29
[22]应卫勇,张海涛,马宏方,房鼎业,管壳外冷-绝热复合式甲醇合成反应器的应用,化工进展,2009,28,419-422
[23]徐兆瑜,甲醇产业的发展和工艺技术新进展,化工技术与开发,2008,37(10),20-26
[24]张殿奎,大型煤气化合成甲醇制丙烯(MTP)是我国煤化工的发展趋势,化工技术经济,2007,25(1),1-4
[25]胡益之,韩冬青,甲醇潜在市场分析,煤化工,2006,34(3),4-5
[26]张刚,王儒,30万t/a甲醇装置技术特点分析,河南化工,2006,23(12)：31-32
[27]李福达,杨志敏,城市煤气联产甲醇设备,河南化工,2007,24(2)：38-39
[28]张学镭,王松岭,陈海平等,焦炉煤气利用项目的经济性评价,现代化工,2006,26(1),47-50
[29]董秀勤.甲醇生产工艺技术简介.内蒙古石油化工,2007(07),38-40
[30]张飞,姜健准,张明森,甲醇制低碳烯烃催化剂的制备与进展,石油化工,2006,35(10),919-923
[31]汪家铭,日本MFR新型甲醇合成塔,四川化工,2006,9(1)：54-55
[32]范济民,杨旺,申峻,合成气的工业应用与催化剂研究进展,煤化工,2006,34(4)：14-17
[33]高晋生,张德祥,甲醇制低碳烯烃的原理和技术进展,煤化工,2006,34(4),7-13
[34]粱淑萍,浅谈甲醇下游产品的发展前景,纯碱工业,2000,(3),46-48
[35]张建国,宋昭峥,丁宏霞,增产丙烯的技术进展与我国发展对策,现代化工,2006,26(增2),5-9
[36]《现代化工》编辑部,甲醇制烯烃工艺与烯烃裂解工艺一体化示范装置,现代化工,2006,26(5),70
[37]《化工中间体》编辑部,煤化工成为世界经济热点,化工中间体,2006(12),401
[38]易丽丽,江海光,唐浩东,甲醇的应用及下游产品开发研究评述,浙江化工,2003,34(12),26-28
[39]薛彩霞,陈玉涌,甲醇工业发展方向及应用,应用化工,2006,35(5),382-384
[40]肖海成,甲醇合成反应器概述,云南化工,2002,8(4),11-13
[41]刘鸿生,朱德林,国内外主要低压甲醇合成塔特性简介,甲醛与甲醇,2003,(2),32-33
[42]Mahajan A, Kirwan D J Micromixing effects in a two impining jets precipitator A IChEJ,1996,42(7):1801-1814.
[43]Cornthwaite, Derek(Chicago,IL), Methanol synthesis catalyst, US:36-39
[44]Short, Glyn D(Cleveland, GB), Jennings, James R.(Cleveland, GB), Catalytic process, US:513-516.
[45]Strel S. Mega-methanol and what to use it for, Nitrogen Se & Methanol, 2001,254(6),23-30.
[46]Keil F J. Methanol to hydrocarbons, process technology, Microporous and Mesoporous Materials,1999,29(1-2),49-66.
[47]Grimm P. Six years successful operation of Linde is other mal reactor, Linde Reports on Science and Technology,1991, (49):57-59.
[48]Burch R, Golunski S E, SpencerM S. J Chem Soc, Faraday Trans,1990, 86(15),2-8
[49]Denshchikov V A, Kont ratev, VN, Romashov A N Interaction between two opposed jets Fluid Dynamics,1978,6:924-926
[50]Bagdasarin A J, Bereczky E L, Ishiguro Tet all Investigation of 26 Year Old Hydroprocessing Reactors, A Summary Report The NACE Annual Conference and Corrosion Show.Paper No119-123
[51]Baker K,Sloan J R,Upitis E.Repair of a 21/4Cr-1Mo Petrochemical Reactor.WRC Bulletin,412,1996.
[52]Autor.China leads world in methanol fuel blending. Hydrocarbon Processing March,2008(5),19
[53]Petrochemical handbook methanol. Hydrocarbon Processing,1993(5),190
[54]Sunggyu Lee,Abhay Sardesai Liquid phase met hanol and dimethy her synthesis from syngasl Topics in Catalysis,2005,32:197-207
[55]Jot himurugesan K, J ames G Goodwin J Development of Fischer Tropsch catalyst s for slurry bubble column reactors Catalysis Today,2000,58: 335-344
[56]Giuseppe Biardi, Giancarlo Baldil Three2 phase catalytic reactorsl Catal ysis Today,1999,52:223-234
[57]Krishna R, Sie S T Design and scale up of the Fischer Tropsch bubble column slurry reactor Fuel Processing Technology,2000,64:73-105
[58]Art hur H Lefebvrel Atomization and Spraysl New York:Hemisphere Publishing Corporation,1987:217
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