In manufacturing-developed countries, thermal spraying technology is also relatively high. This is the law. Last year, the total output value of China's thermal spray industry was 1.2 billion yuan, or about US$140 million. The United States has 2.12 billion U.S. dollars, Japan 8.3 billion U.S. dollars, and Germany 500 million U.S. dollars. This shows that China's gap in this area and equipment manufacturing powerhouse.
China's manufacturing industry is still underdeveloped. This is a typical example of thermal spraying technology being exposed in the chemical equipment field.
Thermal spraying technology was invented by a Swiss company and has a history of several decades. China began research and development by the Beijing Institute of Aeronautical Engineering in 1965.
According to Yan Jialin, executive director of the China Surface Engineering Association's Thermal Spray Professional Committee, thermal spray technology uses gases, liquids, fuels or arcs, and plasma arcs as heat sources to heat metal, alloys, cermets, oxides, and carbides. In the molten or semi-molten state, it is atomized by high-velocity airflow, sprayed and deposited on the surface of the pretreated workpiece to form a firmly adhered surface layer. Reheating the sprayed layer to a molten state results in a metallurgical bond between the sprayed layer and the substrate layer. This method is called thermal spraying.
This technology has evolved with the development of the equipment manufacturing industry. All equipment such as pumps, tanks, kettles, pipes, and shafts that can be subject to acid and alkali corrosion and mechanical wear are the targets of thermal spray technology services. After decades of development, thermal spray technology has been continuously upgraded. It has evolved from flame powder spraying and arc spraying to the latest technologies in plasma spraying and explosion spraying. Tailpipes with higher technical parameters can withstand the high temperature of 1700°C flames emitted from the tail of the aircraft. The lower technical parameters such as the exhaust pipes of automobiles have thermal spraying.
The Tianjin Soda Plant has a total of 13 heavy alkali calciners weighing 45 tons. These calciners run at a high temperature of 1000°C all year round, and are severely burned. The furnace boards have to be replaced every year, causing certain losses to the company. Alumina is melted and sprayed on the inner wall of the furnace with a thermal spray technique. The thickness is between 0.08 mm and 0.12 mm. A layer of sealant made of graphite powder and quartz sand is then applied to ensure the coating surface. Does not leave any pores. The anti-corrosion effect is very good and the service life is increased by 2.4 times. Each year, the company saves 135,000 yuan in the cost of steel plates, saves 154,000 yuan in maintenance costs, and increases the production capacity of caustic soda by 16,000 tons per year.
The inner wall of the tube heat exchanger of the ammonium sulfate plant of Dalian Chemical Industry Co., Ltd. is corroded by the sulfur dioxide gas and acid mist of high temperature of 300°C to 450°C for a long period of time. Each year, the tube heat exchanger must be replaced and the corrosion products that have been blocked between the tubes should be cleaned during overhaul. The average service life of equipment is only about 3 years. After spraying the alumina powder material to the pipe with thermal spraying technology, the anti-corrosion effect is remarkable. Until last year, the original equipment has been used continuously for 17 years, reducing costs for companies.
Chemical spray equipments such as Beijing Dongfang Chemical Plant, Beijing Yanshan Petrochemical Company, and Sichuan Vinylon Plant have all used thermal spray technology to solve the problems of corporate anticorrosion and prevention of mechanical wear of shafts.
At present, from the domestic situation, the metallurgical industry is the most used thermal spraying technology, accounting for 20% of the total market; and the petrochemical industry that needs the anti-corrosion and wear-resisting functions accounts for only 5%. Until today, corrosion, mechanical wear, etc. are still the old faults of chemical equipment, and naturally it also affects the overall level of chemical equipment.
Why are chemical companies lacking interest in this technology? The opinion of a person in charge of a company is that some companies do because they do not understand, and some companies are the cause of the system. If the equipment does not cause any accident, the cost will be saved and the situation will be considered by the next person.
As far as chemical companies are concerned, it is very important to be good at using new technologies. The thermal spraying technology with anti-corrosion, wear-resistance, and repair functions is not used. If the equipment or parts are damaged, it will be shut down and replaced. The increase in cost will not be said, and it will inevitably affect production. However, how to let more chemical companies understand and apply thermal spraying technology is a very difficult issue. Thermal spray technology requires intimate contact with chemical equipment.
China's manufacturing industry is still underdeveloped. This is a typical example of thermal spraying technology being exposed in the chemical equipment field.
Thermal spraying technology was invented by a Swiss company and has a history of several decades. China began research and development by the Beijing Institute of Aeronautical Engineering in 1965.
According to Yan Jialin, executive director of the China Surface Engineering Association's Thermal Spray Professional Committee, thermal spray technology uses gases, liquids, fuels or arcs, and plasma arcs as heat sources to heat metal, alloys, cermets, oxides, and carbides. In the molten or semi-molten state, it is atomized by high-velocity airflow, sprayed and deposited on the surface of the pretreated workpiece to form a firmly adhered surface layer. Reheating the sprayed layer to a molten state results in a metallurgical bond between the sprayed layer and the substrate layer. This method is called thermal spraying.
This technology has evolved with the development of the equipment manufacturing industry. All equipment such as pumps, tanks, kettles, pipes, and shafts that can be subject to acid and alkali corrosion and mechanical wear are the targets of thermal spray technology services. After decades of development, thermal spray technology has been continuously upgraded. It has evolved from flame powder spraying and arc spraying to the latest technologies in plasma spraying and explosion spraying. Tailpipes with higher technical parameters can withstand the high temperature of 1700°C flames emitted from the tail of the aircraft. The lower technical parameters such as the exhaust pipes of automobiles have thermal spraying.
The Tianjin Soda Plant has a total of 13 heavy alkali calciners weighing 45 tons. These calciners run at a high temperature of 1000°C all year round, and are severely burned. The furnace boards have to be replaced every year, causing certain losses to the company. Alumina is melted and sprayed on the inner wall of the furnace with a thermal spray technique. The thickness is between 0.08 mm and 0.12 mm. A layer of sealant made of graphite powder and quartz sand is then applied to ensure the coating surface. Does not leave any pores. The anti-corrosion effect is very good and the service life is increased by 2.4 times. Each year, the company saves 135,000 yuan in the cost of steel plates, saves 154,000 yuan in maintenance costs, and increases the production capacity of caustic soda by 16,000 tons per year.
The inner wall of the tube heat exchanger of the ammonium sulfate plant of Dalian Chemical Industry Co., Ltd. is corroded by the sulfur dioxide gas and acid mist of high temperature of 300°C to 450°C for a long period of time. Each year, the tube heat exchanger must be replaced and the corrosion products that have been blocked between the tubes should be cleaned during overhaul. The average service life of equipment is only about 3 years. After spraying the alumina powder material to the pipe with thermal spraying technology, the anti-corrosion effect is remarkable. Until last year, the original equipment has been used continuously for 17 years, reducing costs for companies.
Chemical spray equipments such as Beijing Dongfang Chemical Plant, Beijing Yanshan Petrochemical Company, and Sichuan Vinylon Plant have all used thermal spray technology to solve the problems of corporate anticorrosion and prevention of mechanical wear of shafts.
At present, from the domestic situation, the metallurgical industry is the most used thermal spraying technology, accounting for 20% of the total market; and the petrochemical industry that needs the anti-corrosion and wear-resisting functions accounts for only 5%. Until today, corrosion, mechanical wear, etc. are still the old faults of chemical equipment, and naturally it also affects the overall level of chemical equipment.
Why are chemical companies lacking interest in this technology? The opinion of a person in charge of a company is that some companies do because they do not understand, and some companies are the cause of the system. If the equipment does not cause any accident, the cost will be saved and the situation will be considered by the next person.
As far as chemical companies are concerned, it is very important to be good at using new technologies. The thermal spraying technology with anti-corrosion, wear-resistance, and repair functions is not used. If the equipment or parts are damaged, it will be shut down and replaced. The increase in cost will not be said, and it will inevitably affect production. However, how to let more chemical companies understand and apply thermal spraying technology is a very difficult issue. Thermal spray technology requires intimate contact with chemical equipment.
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