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It is also known that during the "11th Five-Year Plan" period, the fixed assets investment in the petroleum and chemical industries is expected to exceed 900 billion yuan, and petrochemical and chemical equipment investment accounts for about 30% of the total project investment. In addition, according to the National Development and Reform Commission, by 2020, China’s investment in coal chemical industry will exceed one trillion yuan, of which 50% will be invested in equipment. This has created a huge market space for the development of China's chemical equipment industry.
However, coal chemical and petrochemical equipment are mostly large-scale non-standard pressure vessels. Not every chemical equipment enterprise can process it and manufacture it. According to Duan Ruijun, director of the appraisal department of China National Chemical Equipment Association, to process and manufacture large-scale chemical equipment, first of all, there must be design and manufacturing qualification licenses for three types of pressure vessels; there must also be non-destructive testing equipment, heat treatment furnaces, cranes, coiling machines, etc. And testing equipment, such as coiling machine capacity can not be less than 120 mm, hoisting capacity of not less than 200 tons; also have welding, quality assurance and other types of high-quality technical personnel. Duan Ruijun also pointed out that to process large-scale equipment, chemical equipment companies must also have a sound quality management system, marketing system, technology research and development system, and manufacturing management system. There are more than 3,000 companies that process and manufacture chemical pressure vessels throughout the country, but dozens of them are capable of processing large-scale equipment.
Although the market prospects are broad, the threshold is not low. Which small and medium-sized chemical equipment companies, which account for most of the equipment industry, can also participate in the manufacture and processing of large-scale equipment? How do they participate? In this regard, the industry has provided many valuable suggestions.
Walk along the road
The end cap is the end cap on the pressure vessel and is a main pressure-receiving part of a large-scale tower and boiler. Wuxi Qianzhou Xitang Forging Co., Ltd. is a professional manufacturer of sealing heads. Their annual sales revenue has reached 300 million yuan. Last year, the light customer processing business income reached 50 million yuan. According to the CCIN reporter, the annual sales revenue of most small and medium-sized chemical equipment companies is several million to 20 million yuan. And this company's business is to support large companies.
The company’s production manager, Liu Wei, told CCIN reporters that the modernization of modern enterprises is very detailed and that large-scale equipment manufacturing companies cannot pursue large-scale production, and everything is processed and manufactured by themselves. Take seals, large-scale equipment manufacturing companies need to invest tens of millions of yuan if they want to have head-end processing capabilities. This does not include personnel and technical inputs. For example, the pressure vessel certificate for the A3 head must be obtained separately, involving many costs and technical issues. It is very difficult for large companies to be large and complete. Therefore, the company has determined the development direction for large-scale enterprises from the very beginning. Based on this analysis, the company has successively invested in a double-column vertical lathe with a diameter of 3,200 mm and a single-piece weight of 30 tons. The semi-automatic edge trimmer is specially designed for cutting heads and the 8000 mm-diameter well heat treatment furnace is used for X-rays. Flaw detection room, high and low temperature infrared thermometer and other equipment. This provides sufficient hardware assurance for the high quality production of the head. At present, the company can manufacture elliptical, disc-shaped, conical, hemispherical heads, as well as heads with flat heads and titanium heads. Many of the matching heads of the Shenhua Group's coal-to-oil, coal-to-olefins large-scale equipment were manufactured by them.
Guangdong Jiangmen Boying Welding Engineering Co., Ltd. is a small enterprise specializing in surfacing welding of internal and external pressure vessels of pressure vessels such as boilers and gasifiers. From 2008 till now, the company has taken over the surfacing business of four sets of boiler water wall, superheater pipes and superheater tube screens of Foster Wheeler Power Machinery Co., one of the world's leading manufacturers of boilers. On October 11th, the company also carried out surfacing welding on two-piece dry powder pressure gasifier internal parts of Wushenqi Shilin Chemical Co., Ltd., Inner Mongolia, and successfully delivered the equipment to Hangzhou Boiler Group Co., Ltd. The general manager of the company told CCIN that large equipment requires multiple welding processes. There are thousands of types of these welding processes, and it is impossible for a large-scale equipment manufacturing company to fully grasp it. The fully automated welding process developed by the company is to meet the surfacing requirements of large-scale equipment.
In recent years, Jinan Tongzhi Innovation Technology Co., Ltd. has developed products such as coal water slurry burners, pulverized coal burners, methanol converter burners, flame stabilizers, and butterfly valves. The CCIN reporter found that the company frequently wins bids for large-scale petrochemical and coal chemical projects as ancillary products.
Dong Shusen, a senior engineer of Dalian Jinzhou Heavy Machinery Co., Ltd., a large-scale backbone enterprise in the field of petrochemicals and environmental protection equipment manufacturing, said that SMEs are aiming at large-scale equipment, and processing and supporting their required heads, expansion joints, flanges, etc., are involved. The direction and way of manufacturing large-scale equipment. Dong Shusen suggested that SMEs should also aim at areas where large manufacturing companies are reluctant and professional. For example, the spraying of internal parts of gasifiers is difficult for the general gasifier manufacturers to do professionally, and they need to rely on professional companies. Self-controlled valves require wear-resistant, sealed, special-purpose machine tools, and large-scale equipment enterprises cannot be equipped with such equipment. Special machine tools.
Take the road to joint research
In the interview process, the heads of several chemical equipment companies told CCIN reporters that in the field of large-scale equipment manufacturing, if the company has no performance, it is very difficult for owners to trust their orders to themselves. There is an example: In Liaoning, a small and medium-sized equipment manufacturing company was launched last year and had the qualifications for processing and manufacturing gasifiers. However, due to the relatively small size and reputation of the company, it has not yet been found one year later. Order.
For this issue, some experts suggest that small and medium-sized chemical equipment companies can form alliances with large-scale equipment manufacturing companies, focusing on domestic products that require less processing, and that need to be imported. If the attack is successful, it will be able to form a stable and sustainable market for complementary products. For example, the internal parts of Shell gasifiers and GSP gasifiers in China still need to be imported. In addition, currently there are 10 multi-nozzle gasifiers in operation in China and 40 contracts have been signed. According to its head of research and development, Yu Guangsuo, director of the Institute of Clean Coal Technology at East China University of Science and Technology, introduced the instruments, oxygen valves, and diaphragms of the furnace. Coal-water slurry pumps and safety control systems need to be imported. Dong Shusen said that large-scale equipment such as ethylene oxide reactors are still difficult to do in China, and small and medium-sized enterprises can work together with large companies to solve problems.
Sun Yongkui, deputy general manager of Yantai Guotai Chemical Co., Ltd. suggested that in addition to joint ventures with large-scale equipment manufacturing companies, the first set of products could also be developed in cooperation with the owners. For example, no fees or fees can be charged for performance.
Shandong Hengtong Expansion Joint Manufacturing Co., Ltd. is a company that has tasted the sweetness from the cooperative development. Last year, the company successfully developed joint expansion joints for vinyl acetate reactors with the Yanshan Petrochemical Research Institute. Zhu Hairong, head of the company's sales office, told CCIN that the expansion joint jointly developed by Yanshan Petrochemical Research Institute and Yanshan Petrochemical Research Institute has now been installed on Yanshan Petrochemical's vinyl acetate reactor. The entire molding process, with a thickness of 42 mm, completely replaced the import and became National ancillary products of major domestically produced equipment. Therefore, in the process of the nationalization of major national petrochemical equipment, the joint development of ancillary products by small and medium-sized enterprises (SMEs) and relevant scientific research units and large-scale equipment manufacturing companies is a feasible way to share a large-scale equipment market.
Take the road to technical service
Another way for small and medium-sized enterprises to distribute the chemical equipment market is to provide professional technical services. Industry insiders analyzed the compressor as an example.
Zhou Zhenxian, the former chief engineer of Shandong Weifang Shengjian Group, a compressor manufacturer, told CCIN that now that compressors are becoming larger and larger, previous single compressors could supply 1,000 to 2,000 tons of synthetic ammonia to 50,000 to 60,000 tons per year. And so on, and now a single compressor can supply 400,000 to 500,000 tons of synthetic ammonia and methanol per year; refinery and hydrogenation equipment also uses large-scale hydrogen compressors and circulating hydrogen compressors.
The energy consumption of the compressor is very large, so the potential for saving electricity is also greatest. In the process of use, due to the defect of the design of the compressor and the improper use of the compressor, the valve is easy to be blocked, the service life is not long, and the problem of easy leakage of the piston ring is exposed, resulting in serious waste of electric energy. If you cause the suspension of production to bring greater losses to the company. The key components affecting the reliable and continuous operation of the compressor, such as gas valves and piston rings, are not produced by the compressor manufacturers. This requires the use of professional technical service units. Therefore, Zhou Zhenxian suggested that SMEs can undertake the task of providing professional and technical services, diagnose the problems and hidden dangers in the use of equipment, improve the accessories of the equipment, and upgrade the function and economy of the equipment to improve equipment use. The benefits of the enterprise and the reliability of the equipment.
CCIN reporter learned from a company in Shandong that the company is independently developing compressor energy-saving technologies. Through the energy-saving transformation of key components such as compressor valves and piston rings, the ratio of compressor power consumption to total electricity consumption per ton of ammonia can be reduced to 60% of the original; the power consumption of large compressors can be reduced by 10% on the original basis. ~ 15%, tons of ammonia power consumption in the original basis can be reduced by 50 to 100 kwh.
How SMEs Divert Chemical Equipment Market
The "Restructuring and Revitalization of the Equipment Manufacturing Industry" approved by the State Council in February proposed that: To speed up the revitalization of the equipment manufacturing industry, we must rely on the state's key construction projects to carry out large-scale independent technical and equipment work. The domestic market's domestic market satisfaction rate should be stable at 70. %about. As one of the top ten revitalization industries, the petrochemical industry will use complete sets of equipment for 10 million tons of oil refining, millions of tons of large-scale ethylene, terephthalic acid (PTA), large chemical fertilizers, large-scale coal chemical and natural gas transportation and storage, and Large-scale centrifugal compressors, large-capacity compressors, key pump valves, reaction heat exchangers, extrusion granulators, large-scale air separation plants, cryogenic pumps, etc. are the key points for advancing the automation of petrochemical equipment. Analysis of the industry, coal chemical industry and other industries complete sets of equipment, coal gasifier, low-temperature methanol wash, desulfurization tower, synthesis tower, etc., the market has great potential. This is a rare opportunity for chemical equipment manufacturing industry.