Large-scale extrusion granulation unit project started in Dalian Rubber & Plastics

Recently, China's petrochemical industry is the last bastion of one million tons of ethylene engineering key equipment, and the national “Eleventh Five-Year” major technological equipment research project—large-scale extrusion granulation unit in Dalian Rubber Plastic Machinery Co., Ltd. (hereinafter referred to as Dalian Rubber and Plastics Co., Ltd. held a groundbreaking ceremony. The commencement of this project has not only had a major impact on the large-scale ethylene project in China's petrochemical industry, but also has enabled Dalian Rubber and Plastics' dream of pursuing the past 20 years to become a reality.
deep meaning
At the ceremony, Cao Xianghong, chief engineer of China Petrochemical Corporation and academician of the Chinese Academy of Engineering, said that ethylene is the core product of the petrochemical industry. Extrusion granulation is one of the most basic and important links in the ethylene production process. Large-scale extrusion granulation units It is the key equipment for large-scale ethylene plant reprocessing. For a long time, China’s large-scale production equipment for ethylene has all depended on imports. Although the country has initiated research and development projects since the 7th Five-Year Plan, there have been no major breakthroughs. The core technology of this project has always been in the hands of three manufacturers, such as Japan and Germany, and formed a technology and price monopoly. Prices have doubled in the past five years. The price of a 300,000-ton extrusion granulator has increased from 5-6 million US dollars in 2002 to nearly 10 million US dollars, and the delivery time has been extended from 10 to 12 months to 18 to 24 months. Severely affecting the progress of investment control and construction of China's petrochemical engineering projects has restricted the rapid development of China's petrochemical industry. Therefore, the realization of the domestic production of large extrusion granulation units is our pursuit for many years. Its significance, impact and technical difficulty are no less than ethylene's "three machines" (crack gas compressors, propylene compressors, ethylene compressors).
At the end of 2006, after careful analysis of the equipment level of China's equipment manufacturing industry, the research results of the mixing extrusion granulation theory, and the engineering development and design capabilities of large-scale extrusion granulation units, Sinopec made a very risky decision-making decision. Dalian Dalian Plastics, Beijing University of Chemical Technology, Yanshan Petrochemical and other units jointly tackle the problem. So far, the project's technical research and development work has been fully completed, entered the key stage of Dalian rubber and plastic processing trial production, and is expected to be completed in March next year production, installation, commissioning.
Marking the world advanced
Dalian Rubber and Plastics is an old company with a history of nearly one hundred years. From the mid-50s of the last century, the country began to develop and produce rubber and plastic machinery. After several generations of hard work, it has now developed into the largest and most advanced R&D and manufacturing capacity of rubber and plastics machinery. It has specialized in the production of leading factories and export bases. It has created more than 60 rubber and plastics machinery in China, and has repeatedly taken over the country. Major project localization tasks.
In the petrochemical industry, the large-scale mixed extrusion granulation units for the ethylene production facilities, with an output of 4 to 50 tons per hour, have been designed, manufactured, and installed and commissioned by a few foreign companies and have controlled Markets, including our country. Therefore, as the backbone enterprise of China's rubber and plastics machinery industry, Dalian Rubber and Plastics has been paying attention to and tracking this relationship to the petrochemical industry's ethylene industry among the world's most advanced milestone projects in the past 20 years.
Dalian Rubber and Plastics began its technological reserves by issuing single-screw large-scale extruders from the “July 5” countries. During the "Eighth Five-Year Plan" period, the company successfully developed the 10,000-ton ABS twin-screw large-scale mixing and extrusion granulator technology with international standards. However, due to the fact that all domestic petrochemical industries used imported equipment at the time, users were inexperienced with domestic equipment that had no performance. Because there is no performance, there is no qualification for bids, so this result was put aside and it was put on hold for several years. In spite of this, Dalian Rubber and Plastics did not change its original intentions, and the whole machine could not be made from components. Since the mid-1990s, Dalian Rubber & Plastics Co., Ltd. has cooperated with world-famous large companies to introduce technologies for digesting and absorbing key components such as screws and compressors for the world's most advanced large-scale mixed extrusion granulation units, and has become China's rubber and plastics industry. The first exporter of key components for large-scale mixing extrusion granulation units.
In order to accumulate and enrich the experience of designing and manufacturing large-scale mixing extrusion granulators, Dalian Rubber has been serving Yanshan Petrochemical, Qilu Petrochemical, Tianjin Ethylene, Yangzi Petrochemical and other large domestic petrochemical enterprises for many years, not only for the development of Yanshan Petrochemical. The granulation units also provided and modified spare parts for the imported equipment of these enterprises. While establishing good cooperative relations with these large-scale petrochemical enterprises, they also laid the foundation for further cooperation. In the mid 90s of the last century, Yanshan Petrochemical had caused a major accident due to imported equipment, which caused the company to face the threat of production suspension. It was a key component of Dalian Rubber & Plastic's high-quality and promptly-placed services to solve the urgent needs of the company; the introduction of 300,000 tons The large-scale left and right rotor screws, gearboxes and complete gears provided by ethylene equipment have exceeded the quality of imports. These achievements not only won the praise of users, but also greatly surprised foreign businessmen. Not only that, the company also used these products to open up the world market, so that China's rubber and plastic industry once appeared in the wall flowering wall incense phenomenon. These parts were exported to foreign countries and then assembled by foreign parties and sold to the world's major petrochemical companies including China. They have undergone long-term operational tests and have not experienced any quality problems so far. Through the manufacture and modification of key components for imported equipment, Dalian Rubber and Plastics has freely mastered the design and manufacturing technologies including the core parts of the combined screw and barrel and other key technologies, greatly improving Dalian Rubber Plastics Co., Ltd. The ability of the granulator to localize the task.
Conquering "magnification theory"
Dalian Rubber and Plastics has been committed to the study of "magnification theory" for years at no cost. Yang Lanren, chief engineer of Dalian Rubber and Plastics, told the reporter that “magnification theory” is the core technology of large-scale extrusion granulation units. Large-scale extrusion granulation units ranging from 10 tons to 20 tons and even 50 tons are by no means simple amplifications. As a result of a qualitative leap, as the core technology of large-scale extrusion granulation units, “magnification theory” has always been a technical barrier for large foreign companies to restrict China. They believe that the Chinese will definitely not enter this threshold. However, what caught them by surprise was that Dalian Rubber and Plastics had been quietly getting started after years of hardship.
In recent years, for the development and development of large-scale extrusion granulation units, Dalian Rubber has invested heavily in the introduction of IDEAS 3D software and ANSYS finite element analysis software to perform 3D solid modeling analysis and assembly analysis on the key components of the granulator. Strength analysis and stiffness analysis, etc.; invested heavily in the establishment of the extrusion granulator experimental machine, through the simulation of the material in the extrusion process of temperature conduction and cooling process, material flow, etc., so that "magnification theory" In Dalian Dalian gradually matured. At the same time, Dalian Rubber has also used the production license for the introduction of foreign twin-screw extruders to conduct technical exchanges with foreign large companies, digest and absorb imported prototypes, dispatch engineering and technical personnel, management personnel and operating workers to go abroad for training. The resin granulation process design, mechanical and electrical control design theory and test methods of the extrusion granulator have accumulated a wealth of design, manufacturing technology and management skills for large-scale extrusion granulators, in order to successfully achieve large-scale extrusion. The localization of grain units has created favorable conditions.
Regarding the processing and manufacturing of key parts of large-scale extrusion granulation units, Dalian Rubber and Plastics has completely relied on its own strength for many years. On the basis of guaranteeing normal production, it has established a large-scale production base and gradually increased investment in technological transformation. The key equipment necessary for processing and manufacturing of large-scale mixing extrusion granulation units. Such as CNC screw milling machine, deep hole drilling boring machine, CNC gantry machining center, and CNC vertical machining center, solves the problems of various screw core shafts and various large-sized screw element processing complex; in order to meet the cylinder "CO The requirements for the accuracy and surface roughness of the size of the double-hole machining are also introduced. The CNC double-column vertical car (grinding machine) is also introduced. The large CNC wire-cutting machine guarantees various round holes, spline holes and various angles. Hole-shaped precision machining; CNC forming precision grinding machine, can completely guarantee the precision machining of gearbox and screw elements in various gearboxes; precision CNC roll grinder and extra-large light cylindrical grinder, which made the same industry in the past It is impossible to realize the processing of various parts such as rolls, screws and precision rollers; the CNC horizontal milling boring machine and the CNC horizontal machining center controlled by computer are used to achieve the excellence of various types of precision gear boxes and barrel parts. Pulsed vacuum plasma multi-purpose furnaces and large well gas nitriding furnaces, as well as new large well-type chrome plating tanks, make Dalian Rubber and Plastics the strongest in the Northeast Gas nitriding and the maximum capacity hard chrome processing center.
At present, over 700 sets of CNC machine tools, including resin sand molding production lines, and more than 700 sets of advanced, modern, and modern equipment have been established. Hundreds of thousands of square meters of modern new factory area make Dalian Rubber and Plastics become the most powerful enterprise in China's rubber and plastics machinery manufacturing industry, and it also lays a solid foundation for the early birth of domestic large-scale extrusion granulation units.

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