Localization of coal gasifier is a bit difficult
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Faced with such a huge market, how can the domestic new coal gasifier's processing and manufacturing capabilities be? Can domestic equipment manufacturing support large demand? What problems still exist in domestic manufacturing and processing? The reporter recently interviewed a number of industry experts and business people.
Not many companies can make furnaces
China began to introduce coal gasification technology in 1988. In 1991, the first Texaco coal gasifier introduced was manufactured in China, and Dalian Jinzhou Heavy Machinery Co., Ltd. manufactured China's first Texaco coal gasifier for the Yannan Lunan Fertilizer Plant. This became the starting point for localization of coal gasifiers. According to Yu Guangsuo, head of research and development of an independent domestic multi-nozzle gasifier and director of the Clean Coal Technology Research Institute of East China University of Science and Technology, more than 30 sets of multi-nozzle gasifiers currently in operation and under construction in China are all made of domestic materials in China. manufacture. However, currently there are not many companies that have the capability to manufacture coal gasifiers.
"As the core and key equipment for coal gasification, coal gasifiers, despite their different gasification methods, are all products with complex equipment structure, high material requirements, high precision requirements, long construction period, high quality requirements, and difficult manufacturing." Zhao Mengqing, deputy secretary-general of China National Chemical Equipment Association, told reporters.
“To overcome various technical difficulties in gasifier manufacturing, general equipment manufacturers cannot do this.†Dong Shusen, a senior engineer at Dalian Jinzhou Heavy Machinery Co., Ltd., told reporters. According to him, for example, multi-nozzle coal gasifier, the four nozzles on the side wall should be evenly distributed at 90 degrees, the plane deviation should be no more than 0.5 mm, the verticality deviation should be no more than 1 mm, and the axis of each two opposite nozzle nozzles must also be Coincidence, which requires precise control, requires high-precision measurement technology support. In addition, the problem that internal diameters of the shells of the quenching chamber are easily “shrunk†after the internal surface of the quenching chamber is surmounted is also a technical problem in the manufacturing process.
“The structure of the Shell coal gasifier is relatively complex and it is more difficult to manufacture and manufacture,†said Zhao Qingwan, head of the gasifier of the Chemical Industry Equipment Quality Supervision and Inspection Center. According to him, the Shell coal gasifier consists of four components, the gasifier shell, the conduit shell, the gas return chamber shell, and the waste heat boiler shell. Each set of coal gasifier has a total weight of about 1,000 tons, which is overweight, Excessive equipment. The four parts are processed and formed separately at the manufacturing plant, and are pre-assembled with the internal parts, and then disassembled and transported to the owner's site for separate assembly and welding in the air. The air group is difficult and adjustment is very inconvenient. It is very important to make precision, pre-assembly and measurement work.
Zhao Mengqing pointed out that the processing and manufacturing of coal gasifiers is a manifestation of the comprehensive capabilities of the hardware and software of mechanical equipment companies. At present, there are only a dozen machinery and equipment companies that have the ability to manufacture and produce coal gasifiers in China, including only China First Heavy Machinery Group, Dalian Jinzhou Heavy Machinery Co., Ltd., and Harbin Boiler Works.
"The more than 10 companies, each company's processing and manufacturing capacity for a year at most only 10. If the formation of a large number of demand, or simply the more than 10 companies simply can not produce." Wen Jianwei told reporters.
Difficulties in processing steel inside and outside
“At present, the main materials required for processing and manufacturing of domestic gasifiers are steel products of the type SA387Gr11CL2 imported from Japan, Germany, Sweden, etc. The performance is equivalent to domestically produced 14CrMoR steel products. The market price of imported steel products is Nearly 60% higher than domestic, the minimum purchase time is 8 months, which is half of that in China. Wen Jianwei told reporters.
Since domestic steel products have the same performance as imported steel products, and imports are not only expensive, but also have a long delivery time, why do you have to choose to import more? According to the reporter's understanding, there are two reasons for this.
On the one hand, the user requires imported steel. Wen Jianwei said, “Because users believe that the quality of domestic steel is not reliable, they will be required to choose to import when placing orders.†It is understood that the consumption of steel in the production of coal gasifiers is very large and a Shell coal gasifier will consume More than 1,000 tons of steel, coal-water slurry gasifier also consumes about 200 tons of steel. In this way, if the user selects imported steel, the cost per gasifier is 60% higher than that of domestic steel.
“Choose whether to import steel or domestic steel. Ultimately, the decision will be made by the user. In fact, the quality of domestic steel is still good, there is no problem, mainly lack of publicity and promotion.†Dong Shusen told reporters. According to him, the operating conditions of the gasifier are harsh and the steel used for processing is demanding. Although the domestically produced CrMo steel does not meet the requirements of the key parts of the gasifier, as long as relevant special indicators are provided to the steel producers, they Can also provide products that meet the requirements. And the use of domestic steel can shorten the user's schedule and reduce project investment costs.
On the other hand, domestic steel supply is relatively tight. It is understood that, with the maturation and industrialization of multi-nozzle gasification technologies, space furnaces and other domestic autonomous gasification technologies, most of the steels used in these gasifiers are mainly made in China. The domestic CrMo steel can only be produced by a company in Henan Wuyang Iron and Steel Co., Ltd., which is the first production base for steel plates in China. The reporter learned from Wuyang Iron and Steel Company that their current production capacity is limited and they can only be limited. The staff of the sales department of the company told the reporter that at present, they still owe 450,000 tons of steel to several gasifier manufacturers. Several gasifier processing and manufacturing companies also confirmed to reporters that domestic steel supply is very tight.
Xu Caifu, deputy chief engineer of Wuhuan Technology Co., Ltd., told reporters that in the past two years, other domestic steel mills will also produce steel for coal gasifier processing. The problem of tight steel supply and long delivery time is expected to be improved.
Tax policy also blocked
According to industry insiders, for a long time, the domestic design and manufacture of advanced coal gasifiers have relied on imports, and the introduction of coal gasification equipment is expensive, and it has to pay hundreds of millions of dollars for proprietary equipment processing and on-site technical services. The cost of the company has been greatly increased, and it has also affected the development of the coal chemical industry to some extent. The domestic production of coal gasifiers is an important measure to reduce investment in projects and improve industrial competitiveness, and is an important guarantee for the healthy development of coal chemical industry in China. Therefore, the manufacture of coal gasifiers is an important part of China's major equipment manufacturing industry, and it should be supported by relevant national policies. However, the reporter learned from the interview that the existing relevant policies are actually blocking the localization of coal gasifiers.
In accordance with relevant policies, the current major technological transformation projects in China and the use of foreign investment in imported machinery and equipment products can enjoy the tax exemption, while the equipment manufacturing industry to achieve the localization of imported materials and accessories but need to pay the full tax. Industry sources said that this approach will affect the enthusiasm of localization of coal gasifiers. As mentioned before, the domestic supply of special steel for domestic coal gasifiers is insufficient and needs to be imported from abroad. According to the existing equipment import taxation policy, the steel products imported from the production of coal gasifiers and other related important accessories must be subject to tax, which greatly increases the cost of domestic coal gasifiers. This undoubtedly limits the localization of coal gasifiers.
Therefore, many manufacturing companies hope that through the call of the reporter, the state should implement preferential taxation on the imported materials and accessories required for localization of coal gasifiers, and at the same time, invest and gasify domestically developed coal gasifier processing and manufacturing equipment. Furnace products are directly tax-exempt. In addition, the state should also formulate policies that encourage the promotion of domestic gasifiers, and encourage enterprises that use domestic coal gasifiers to adopt investment subsidies, tax relief, and other policies to create a better policy environment for domestic coal gasifiers.