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On April 28, China's major equipment manufacturing field broke new records again. The 2.6 million tons/year fluidized bed residual oil forging and welding hydrogenation reactor with a total weight of 2,400 tons was successfully manufactured at SINOMACH Zhenjiang Company. On the same day, this gigantic "behemoth" was hoisted onto the ship by the "First Crane of Wanli Yangtze River" and shipped to users.

This hydrogenation reactor developed by Erzhong Equipment, a core manufacturing enterprise of Sinomach Heavy Equipment Group Co., Ltd. (SINOMACH) affiliated to China National Machinery Industry Corporation (SINOMACH), is the first boiling reactor in the domestic oil refining sector. The bed residue hydrogenation reactor has created two "world firsts" in today's hydrogenation reactors in the world - one is the "world's first" in product weight. This hydrogenation reactor has a total length of more than 70 meters and an outer diameter of 5.4 The weight is 2,400 tons; the second is the complexity of manufacturing technology "the world's first", its manufacturing technology and complexity have broken through the world hydrogenation reactor limit manufacturing record.

Not long before that, on March 28, 2018, my country's first high-end heavy equipment manufacturing flagship integrating science, industry and trade - SINOMACH was officially established. At the time of setting sail, SINOMACH made its first show of strength, that is, launched the "heaviest weapon of the country" fluidized bed residual oil forging and welding hydrogenation reactor, breaking multiple world records in the limit manufacturing of similar products, fully demonstrating the transformation of major equipment manufacturing The majestic "Chinese power" bursting out of China.

The 2.6 million tons/year fluidized bed residual oil forging and welding hydrogenation reactor is the core equipment in my country's oil quality upgrading project. After the project is completed and put into operation, the conversion level of residue oil can be improved to the greatest extent, and the conversion rate of residue oil can be increased to 85%, while the original device is only 40%-50%. At the same time, reducing the load of delayed coking and increasing the production capacity of light oil will make PetroChina's refining and chemical technology rank among the world's advanced ranks, which will strongly support the implementation of the national energy strategy. This is the "national important weapon" for national energy security and "beautiful China" construction.

Because the product is oversized, overweight and out of limit, its transportation, hoisting, and delivery have also created a new domestic overall combined hoisting record—the total weight of the product and hoisting aids has reached an astonishing 2,500 tons. SINOMACH Zhenjiang Company has two cranes with a lifting capacity of 850 tons, and the total lifting weight at one time reaches 1,700 tons. This is the largest lifting capacity on the Yangtze River waterway, known as "the first crane on the Yangtze River for thousands of miles". And the weight of 2,500 tons has far exceeded the limit capacity of "the first crane on the Yangtze River for thousands of miles". In order to ensure the success of the hoisting and shipping, two 850-ton cranes and 1,600-ton non-self-propelled floating cranes were used for joint hoisting, creating a new record for the largest weight hoisting in the history of the Yangtze River waterway.

Structural adjustment and upgrading of petroleum refining and chemical industry are related to national energy security, and are major measures for technological progress of the petroleum refining and chemical industry. The 2.6 million tons/year quality improvement and upgrading project is an innovative project to implement the national energy strategy and create a residue hydrogenation technology system with independent intellectual property rights. The manufacture of its core equipment, the fluidized bed residual oil forging and welding hydrogenation reactor, is the key to the success of the whole project. When accepting the manufacturing task of fluidized bed residual oil forging and welding hydrogenation reactor, it was the time when China National Machinery Industry Corporation (SINOMACH) implemented the strategic deployment of the State Council and the State-owned Assets Supervision and Administration Commission of the State Council, and built a Integrating science, industry and trade, it is the start of a major equipment manufacturing flagship enterprise.

In October 2016, while intensively promoting the reform of the system and mechanism with the goal of building the capability of the whole industry chain of high-end equipment, a hydrogenation reactor extreme manufacturing battle started. SINOMACH wants to demonstrate its extreme manufacturing capability and excellent service to the global market.

Due to exceeding the manufacturing limit, every process, every link, and every process of the manufacturing process must be carefully planned and repeatedly calculated. Only the final assembly and transshipment at Erzhong Zhenjiang Company, because the product is assembled and welded by three sections, each weighing more than 800 tons, not only the foundation of the manufacturing site and production workshop must be reinforced, but also the passing roads and approach bridges must be reinforced. To carry out transformation and clearing obstacles, it is necessary to accurately calculate the tooling and auxiliary tools required for production, lifting equipment, and even the maximum load-bearing capacity of a steel wire rope. No mistakes are allowed, and a single mistake will lead to unimaginable consequences. .

This is a large cross-professional, cross-system, and cross-regional manufacturing collaboration that requires careful and detailed deployment of technology, equipment, materials, manpower, funds, and logistics support. While the manufacture of fluidized bed residual oil forging and welding hydrogenation reactors is in full swing, the reform of the system and mechanism around making it better and stronger is also stepping up. The party and government team of SINOMACH believes that in order to truly transform the dual-limit manufacturing capacity into the core competitiveness of the company's high-quality development, it is necessary to seize the great opportunity of the supply-side structural reform and carry out reforms around organizational reform, business model reform and capacity improvement. Asset restructuring. Inject China Heavy Industry Institute and China Heavy Machinery into Erzhong's main business, completely solve the problems of Erzhong's insufficient scientific research, technology and market capabilities, and build Erzhong into a heavy equipment group that can keep pace with the world's top equipment manufacturing enterprises. With the advancement of system and mechanism reforms, Erzhong's comprehensive strength exploded in the manufacture of fluidized bed residual oil forging and welding hydrogenation reactors.

In 2017, the research on the forging and welding hydrogenation reactor of fluidized bed residual oil was carried out one after another. Forging is the first to bear the brunt. According to the design requirements, the cylinder body of the hydrogenation reactor needs to be smelted and poured into steel ingots forged from high-quality molten steel. The entire cylinder body is formed by forging and welding 17 large steel ingots. Each section of the forged cylinder must reach the level of a first-class forging. The homogeneity and performance requirements of the finished product are extremely strict, which is a typical large-scale precision forging. In order to achieve a success, the forging masters of Erzhong Equipment used their exquisite skills to cook 17 dishes with the same requirements. The ultimate manufacturing capacity of double equipment.

The fluidized bed residual oil forging and welding hydrogenation reactor contracted by Erzhong Equipment is the first stage of the oil quality upgrading project. It needs to withstand the erosion and erosion of various acids, and the working environment is the most severe. Therefore, users put forward particularly strict requirements on the performance of the equipment body and the internal stainless steel corrosion resistance layer. What is even more difficult is that the Mo content of the corrosion-resistant layer 316L of the inner wall material of the cylinder is not less than 2.5%. There is no precedent to follow in the manufacture of similar products in the world, and there is no mature process for reference. In the day and night of research, the skilled masters of Erzhong Equipment have realized the 309MoL+316L surfacing welding with high Mo requirements for super large steel hydrogenation reactors with superb welding technology and unique technological means, creating a precedent for the manufacture of similar products and filling the gap. It has filled the blank of surfacing welding technology for similar products in the world.

With the completion of single-piece barrel section forging, inner wall surfacing and performance heat treatment in the Deyang manufacturing base, all product components are sent to the SINOMACH Zhenjiang Estuary Base to enter the stage of assembly and welding. Zhenjiang, from the late autumn in the south of the Yangtze River to the fireworks in March of 2018, among clusters of beautiful welding flowers, the ebullated bed residual oil forging welding hydrogenation reactor representing the world's highest manufacturing level was born.

The load-bearing capacity of the workshop has been improved, cross-area reversing, cross-area welding and post-weld heat treatment, one problem after another has been solved. Synchronous manual welding of plug-in joints, "horizontal" assembly of distribution plates, downcomers, nuclear source protection sleeves, etc., one after another high-precision welding assembly miracles have been realized. The hydrostatic test was a success.

During the Spring Festival of 2017, more than 280 Erzhong Equipment employees stuck to the production site of the Zhenjiang Base and performed a unique "Spring Festival Gala" with gorgeous welding flowers. When the lower head took over the nickel-based welding between the upper dissimilar steels, the equipment workers created an over-limited breakthrough to complete a month's worth of tasks in a week. Technical, management, testing, and welding personnel worked continuously for 30 hours to complete the last main weld welding assembly. The Erzhong Equipment craftsman team, represented by Erzhong Equipment's national labor model and representative of the 19th National Congress of the Communist Party of China, Li Xiang, a national skill master, and Liao Yong, a senior technician, completed 2.6 million tons per year with superb skills and tenacious struggle. The extreme manufacturing feat of the fluidized bed residual oil forging and welding hydrogenation reactor interprets the demeanor of industrial workers in the new era.