A manufacturing process for a gas phase reactor distributor

Abstract

The application belongs to the field of reactor preparation process, and specifically discloses a manufacturing process of a gas-phase reactor distributor, which comprises the following procedures: cylinder section forming process, cylinder section assembly welding, cross beam assembly welding, and assembly of cross beam support ring assembly, etc. Through the cylinder body connecting pipe welding process, cylinder body forming size control, support ring coiling forming process control, support ring assembly welding process, cross beam and cylinder body assembly welding process influence on the cylinder body roundness, development of the bolt hole drilling process on the outermost support ring, the flatness, roundness and bolt hole positioning size precision of the support ring are finally ensured, thereby meeting the installation precision requirement of the distributor plate and the support ring through the bolt hole after the reactor is shipped to the use site, and finally ensuring that the flatness of the support ring reaches 0.2mm, the roundness reaches 2mm, and the positioning size precision of the bolt hole is within the deviation range of 1mm.

Description

TECHNICAL FIELD

[0001] The application belongs to the field of reactor manufacturing process, and specifically discloses a manufacturing process of a gas-phase reactor distributor. BACKGROUND

[0002] Polypropylene is a thermoplastic resin prepared by polymerization of propylene. According to the arrangement position of methyl, it is divided into isotactic polypropylene, atactic polypropylene and syndiotactic polypropylene. Polypropylene is a non-toxic, odorless, tasteless, milky white high crystalline polymer, and is one of the lightest varieties among all plastics at present. It has good formability, good gloss on the surface of the product, good heat resistance and corrosion resistance, and the product can be sterilized by steam, which is the outstanding advantage of polypropylene.

[0003] With the continuous improvement of the production capacity of polypropylene devices in China, high-efficiency gas-phase reactors emerge as the times require, and the dimensional precision requirements of products are higher, the technical level requirements are higher, and the manufacturing difficulty is greater. It is very important to develop and research high-performance gas-phase reactors. The development of high-precision product manufacturing technology for gas-phase reactor equipment faces a series of core technical problems: the distributor is a core and key component in the gas-phase reactor, and the manufacturing precision directly affects the performance of the product. (1) The distributor is composed of a distribution plate, a support ring and a cross beam. The support ring and the cross beam are support components of the distribution plate, the distribution plate is connected with the support ring through bolts, and the manufacturing precision directly affects the installation precision of the distribution plate. The support ring and the cross beam have many connections with the cylinder section, and welding is easy to cause deformation, thereby causing the deviation of the roundness of the cylinder body. Therefore, controlling the roundness precision of the cylinder section can provide a good assembly basis for the support ring in the distributor. (2) The assembly gap between the support ring in the distributor and the cylinder body is only 2mm. The nearly 4m support ring is assembled in the cylinder section, and the roundness of the support ring itself is required to be very high. Because the height of the support ring is relatively short, the size of the two ends cannot be controlled when it is rolled, the outer circumference is easy to be rolled long, and a conical cylinder is easy to be formed. Measures need to be taken to ensure the roundness and the perpendicularity of the outer diameter. (3) The roundness and flatness of the outermost support ring and the support ring on the inner cross beam directly affect the installation precision of the distribution plate. (4) The positioning support of the bolt hole on the outermost support ring requires accurate correspondence. Only a diameter of 10mm bolt passes through a φ13mm round hole of the support plate, which is equivalent to a single-sided assembly clearance of 1.5mm, and the manufacturing precision is required to be high. (5) The outermost support ring is welded with the inner wall of the cylinder body. The stainless steel support ring is easy to deform after welding. The control of the welding process scheme and the welding sequence is very important. The height difference control precision of the outermost support ring and the four inner support rings directly affects the flatness of the distribution plate on site and the relative size requirements of the bolt hole. (6) The polishing precision of the inner wall of the equipment is high. The inner part welding seam needs to be polished. The polishing precision reaches Ra0.8. The polishing precision of the inner wall of the equipment directly affects the product quality and safety performance of the product. If the polishing precision is not up to standard, the wall hanging phenomenon is easy to occur, which affects the normal operation of the equipment. SUMMARY

[0004] To address the aforementioned issues, this invention discloses a manufacturing process for a gas phase reactor distributor. By controlling the welding process of the cylinder nozzle, the forming dimensions of the cylinder, the rolling and forming process of the support ring, the welding process of the support ring assembly, the influence of the welding process of the grid beam and the cylinder assembly on the roundness of the cylinder, and the development of the drilling process for the bolt holes on the outermost support ring, the flatness, roundness, and bolt hole positioning dimensions of the support ring are ultimately guaranteed. This ensures that the accuracy requirements for the installation of the distribution plate and the support ring through the bolt holes are met after the reactor is shipped to the site.

[0005] The present invention adopts the following technical solution:

[0006] A manufacturing process for a gas phase reactor distributor includes the following steps:

[0007] A manufacturing process for a gas phase reactor distributor, characterized by comprising the following steps:

[0008] S1. When forming the cylinder, control the diameter to be 2mm larger than the size required by the drawing. When cutting the steel plate for the cylinder, control the length dimension of the plate to be 6mm larger than the size required by the drawing.

[0009] S2. Before welding the tube to the cylinder assembly, add a supporting arc plate and steel pipe on the inner side before welding the tube. After adjusting the roundness of the cylinder to be qualified, add two outer hoop rings and 20 stiffening plates on the outer side of the cylinder to increase the control of roundness. At the same time, when assembling the tube, the tube is 1-3mm higher than the cylinder. During welding, it is supported by the supporting arc plate and steel pipe and raised 1-3mm in the opposite direction.

[0010] S3. When cutting the outermost support ring steel plate, add a 4-6mm allowance. After the outermost support ring is rolled in sections, fix it with two longitudinal seams and spot welding. Add a process support ring on the inner side to make it round. When rolling the outermost support ring, the inner diameter is 3-5mm less than the size required by the drawing. After the pipes and grid beams on the cylinder are all welded together, measure the actual inner diameter of the cylinder and then process the outer diameter of the outermost support ring. Weld the two longitudinal seams of the outermost support ring before assembling it into the cylinder.

[0011] S4. The support ring is inserted and welded onto the grid beam. When cutting the 4-layer support ring, leave a height allowance. After rolling, mark the notch with the lower end face as the reference, weld it to the grid beam, and then process the upper surface of the support ring as a whole.

[0012] S5. When assembling the grid beam and support rings, ensure the coaxiality of the 4-layer support rings with the cylinder, and at the same time ensure that the ends of the grid beam are tightly fitted with the cylinder.

[0013] S6. A top one circle of circumferential fillet welds and a bottom one circle of circumferential fillet welds are welded between the outermost support ring and the cylinder body, 12 long circular holes are uniformly distributed on the outermost support ring, plug welding is adopted, argon arc welding process is adopted, and welding deformation is controlled through strict control of welding sequence;

[0014] During welding, the circumferential fillet welds are welded by adopting argon arc welding, the plug welding holes are filled by adopting the welding scheme of argon arc welding, the gap between the outermost support ring and the inner wall of the cylinder body is filled, and deformation during bottoming welding is prevented; then, φ3.2 electrode arc welding is adopted to control welding heat input and deformation;

[0015] During welding, the sequence of simultaneous operation of multiple people is followed, one layer of plug welding holes is welded at a time, 12 plug welding holes are symmetrically welded at the same time by four people, four plug welding holes one of the first layer are welded first, four plug welding holes two of the first layer are welded then, four plug welding holes three of the first layer are welded, the second layer of plug welding holes one is welded, the second layer of plug welding holes two is welded, the second layer of plug welding holes three is welded, and the third layer of plug welding holes one is welded;

[0016] S7. The threaded holes on the outermost support ring are drilled by adopting a factory-distributed drilling template, the distance between the threaded holes and the inner wall of the cylinder body is only 19 mm, a conventional drilling machine cannot drill holes close to the inner wall due to the large diameter of the drill chuck, and therefore a bevel gear right-angle inverter is used for drilling.

[0017] Further, in the manufacturing process of the above-mentioned gas phase reactor distributor, the diameter of the cylinder body is controlled to be 2 mm larger than the required size in the drawing during forming in step S1, and the length of the steel plate in the plate length direction is controlled to be 6 mm larger than the required size in the drawing during cutting.

[0018] Further, in the manufacturing process of the above-mentioned gas phase reactor distributor, the thickness of the outermost support ring steel plate is increased by 5 mm during cutting, and the inner diameter is formed by subtracting 4 mm from the theoretical value during rolling the outermost support ring.

[0019] Further, in the manufacturing process of the above-mentioned gas phase reactor distributor, in step S7, the bevel gear right-angle inverter is a small bevel gear box right-angle inverter with a speed ratio of 1:1, the diameter of the drill chucking part is changed, the drilling in a small space and close distance is met, and the operability of the drilling space with a distance of only 19 mm between the threaded holes and the inner wall is met.

[0020] Compared with the prior art, the present application has the following outstanding beneficial effects:

[0021] Compared with the prior art, the roundness precision of the formed cylinder is greatly improved. In the traditional mode, the roundness of the cylinder after pipe welding exceeds 10mm, and the plug welding hole in the traditional mode also causes the roundness of the cylinder to increase by 4mm, finally resulting in a roundness deviation of the cylinder of more than 14mm. Through the cylinder pipe welding process, cylinder forming size control, support ring rolling forming process control, support ring assembly welding process, the influence of the I-beam and cylinder assembly welding process on the roundness of the cylinder, the development of the drilling process of the bolt hole on the outermost support ring, the flatness of the support ring is finally ensured to be within 0.2mm, the roundness is within 2mm, and the positioning size accuracy of the bolt hole is within 1mm. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 It is a three-dimensional structural schematic diagram of the assembly relationship of the distributor, cylinder and connecting pipe in the gas phase reactor.

[0023] Figure 2 It is a three-dimensional schematic diagram of the assembly relationship of the support ring, I-beam and outer hoop in the gas phase reactor.

[0024] Figure 3 It is a schematic diagram of the anti-deformation support structure of the cylinder assembly pipe.

[0025] Figure 4 It is a physical diagram of the assembly of the I-beam and the cylinder.

[0026] Figure 5 It is a schematic diagram of the plug welding hole welding sequence on the support ring.

[0027] Figure 6 It is a physical diagram of the installation drilling of the bevel gear right-angle inverter.

[0028] Wherein: 101 is a cylinder, 201 is a factory drilling template, 202-206 are different support rings, 207 is a threaded hole, 208-209 are different longitudinal seams, 210 is a long circular hole, 301 is an arc plate, 302 is a steel pipe, 401 is an outer hoop, 402 is a rib plate, 501-505 are different connecting pipes on the cylinder, 601-602 are different I-beams. DETAILED DESCRIPTION

[0029] The technical solutions in the embodiments of the present application will be described below in a clear and complete manner. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0030] EMBODIMENT

[0031] A manufacturing process of a gas phase reactor distributor, comprising the following steps:

[0032] Step 1. Develop the forming process of the cylinder 101 where the outermost support ring 202 of the distributor is located, in order to ensure the smooth assembly of the outermost support ring 202 and the cylinder 101, the diameter is controlled to be 2mm larger than the theoretical value when the cylinder 101 is calibrated, the length dimension of the steel plate is increased by 6mm in the plate length direction when the cylinder steel plate is cut, the outer circumference will decrease by 3mm when the cylinder longitudinal seam is welded, and the outer circumference will increase by 4mm when the cylinder is calibrated, so the outer circumference length is 7mm larger than the required size on the drawing, that is, the diameter is about 2mm larger than the theoretical value after forming.

[0033] Step 2. Before assembling and welding the pipes 501~505 of the cylinder 101, in order to prevent welding deformation, support arc plates 301 and steel pipes 302 are added on the inside before welding the pipes 501~505 (the arc plates 301 increase the contact area with the inner wall of the cylinder 101 and improve the roundness effect), after adjusting the roundness of the cylinder 101 to be qualified, two layers of outer hoop rings 401 are added on the outside of the cylinder 101, and 20 rib plates 402 are added in the middle of the two layers of outer hoop rings 401, which improves the overall strength of the outer hoop ring and the roundness control effect is better, and when assembling the pipes 501~505, the pipes 501~505 are 1~3mm higher than the cylinder 101, and when welding, the pipes 501~505 are supported by the support arc plates 301 and the steel pipes 302, and the pipes 501~505 are lifted in the opposite direction, finally ensuring that the welded pipes 501~505 are prevented from sinking and deforming.

[0034] Step 3. Because the outermost support ring 202 is relatively narrow, the outer circumference is easy to roll after calibration, in order to ensure that the gap between the outermost support ring 202 and the inner wall of the cylinder 101 is not too large, the thickness of the outermost support ring 202 steel plate is increased by 5mm when cutting, and the outermost support ring 202 is divided into two parts and rolled, and the two longitudinal seams 208 and 209 are spot welded and fixed, the inside is supported by a support ring to round, and when the support ring 407 is rolled, the inner diameter is formed according to the theory-4mm, so that the outer diameter has a secondary processing allowance of 6mm, after the upper pipes 501~505, the cross beams 601 and 602 of the cylinder are all assembled and welded, the actual inner diameter value of the cylinder 101 is measured, and then the outer diameter of the outermost support ring 202 is processed. After assembling into the cylinder 101, the two longitudinal seams 208 and 209 on the outermost support ring 202 are welded.

[0035] Step 4. The welding process of the cross beam 601 and 602 and the support ring 203~206, because the cross beam is composed of 2 601 and 2 602, there are 4 layers of support rings 203~206 on the top, the support ring is inserted and welded on the cross beam 601 and 602, the height difference between the 4 layers of support rings 203~206 and the outermost support ring 202 must be strictly guaranteed, and the flatness requirement must be guaranteed, so the height allowance of the 4 layers of support rings 203~206 is left when cutting, and the notch is drawn after rolling with the lower end surface as the reference line, after welding with the cross beam 501~505, the upper surface of the support ring 203~206 is processed as a whole to ensure that the overall flatness of the four layers of support rings 203~206 meets the requirement of within 0.2mm.

[0036] Step 5. When assembling the cross beam 601 and 602 support ring 203~206 assembly, ensure that the 4 layers of support rings 203~206 and the cylinder 101 are coaxial, and at the same time ensure that the end of the cross beam 601 and 602 is tightly fitted with the cylinder 101, so as to prevent the gap from being too large, causing the weld shrinkage and the deformation of the cylinder roundness. Ensure the roundness of the outermost support ring 202 and the coaxial accuracy of the 4 layers of support rings 203~206 and the cylinder 101.

[0037] Step 6. The outermost support ring 202 and the cylinder 101 are welded with a top ring of circumferential fillet weld and a bottom ring of circumferential fillet weld structure, and the support ring 407 is evenly distributed with 12 long circular holes 210 which need to be plugged. The welding process adopts argon arc welding, the welding deformation is controlled by strictly controlling the welding sequence, the circumferential fillet weld is welded by argon arc welding, the plug hole is filled with argon arc welding, the gap between the outermost support ring 202 and the inner wall of the cylinder 101 is filled, and the deformation during the backing welding is prevented. Then φ3.2 electrode arc welding is adopted to control the welding heat input and deformation. In the welding process, the sequence of 12 3 simultaneous operation is followed, and then one layer of plug hole is welded. The 12 plug holes are symmetrically welded by 4 people at the same time. Four plug holes 1 in one layer are welded first, then four plug holes 2 in one layer are welded, then four plug holes 3 in one layer are welded, then the second layer of 1 is welded, the second layer of 2 is welded, the second layer of 3 is welded, and then the third layer of 1 is welded. The third layer of 2 is welded, and so on. The welding method is shown in Table 1.

[0038]

[0039] Step 7. The outermost support ring 202 is drilled using the factory drilling template 201. The distance between the bolt hole 207 and the inner wall of the cylinder is only 19mm. The diameter of the conventional drill chuck is large, so the drill cannot be close to the bolt hole position of the inner wall of the cylinder 101. Therefore, a drilling modification device is developed to enable the drill with drill bit to be close to the bolt hole position of the inner wall of the cylinder. The bevel gear right-angle commutator can satisfy the process mode of drilling after the support ring and the cylinder are welded, avoiding the problems of deviation of the bolt hole positioning size or the bolt hole being elliptical due to welding deformation after the support ring is drilled and then welded with the cylinder. Using this method, the deviation of the bolt hole positioning size can be ensured to be within 1mm, fully meeting the assembly clearance requirement of the φ10mm bolt and the φ13mm bolt hole on the connecting plate.

[0040] The above merely describes a few preferred embodiments of the present application, which are specific and detailed, but should not be understood as limiting the scope of the patent of the present application. It should be noted that, for those skilled in the art, without departing from the concept of the present application, several modifications and improvements can be made, which are all within the protection scope of the present application.

Claims

1. A process for the manufacture of a gas phase reactor distributor, characterized in that, The method comprises the following steps: S1. When the cylinder (101) is formed, the diameter is controlled to be 2mm larger than the size required by the drawing, and when the cylinder steel plate is cut, the length in the plate length direction is controlled to be 6mm larger than the size required by the drawing; S2. Before the cylinder is assembled and welded with the pipes (501)-(505), the arc support plates (301) and the steel pipes (302) are added on the inner side before the pipes (501)-(505) are welded, the roundness of the cylinder (101) is adjusted, and then two layers of outer hoops (401) and 20 rib plates (402) are added on the outer side of the cylinder to increase the roundness control, and when the pipes (501)-(505) are assembled, the pipes (501)-(505) are 1-3mm higher than the cylinder, and the pipes are supported by the arc support plates (301) and the steel pipes (302) and are lifted reversely by 1-3mm during welding; S3. When the steel plate thickness of the outermost support ring (202) is cut, a 4-6mm allowance is added, the outermost support ring (202) is divided into two parts and is fixed by spot welding after being coiled, the inner side is processed as a support ring, the inner diameter of the outermost support ring (202) is formed by reducing 3-5mm from the size required by the drawing during coiling of the outermost support ring (202), the actual inner diameter of the cylinder (101) is measured after the pipes (501)-(505) and the cross beams (601)-(602) are completely assembled and welded, the outer diameter of the outermost support ring (202) is then processed, and the two longitudinal seams (208) and (209) of the outermost support ring (202) are welded after being assembled into the cylinder (101); S4. The inner support rings (203)-(206) are inserted and welded on the cross beams (601)-(602), the height of the four layers of support rings (203)-(206) is cut with an allowance, and the support rings (203)-(206) are coiled, the slits are marked based on the lower end face, and the upper surfaces of the support rings (203)-(206) are processed after being assembled and welded with the cross beams (601)-(602); S5. When the cross beams (601)-(602) and the support rings (203)-(206) are assembled, the coaxiality of the four layers of support rings (203)-(206) and the cylinder (101) is ensured, and the end part of the cross beam (601)-(602) is tightly attached to the cylinder (101); S6. The top one ring of circumferential fillet welds and the bottom one ring of circumferential fillet welds are welded between the outermost support ring (202) and the cylinder (101), 12 long circular holes (210) are uniformly distributed on the circumference of the outermost support ring (202) and need to be plug welded, the argon arc welding process is adopted, and the welding deformation is controlled by strictly controlling the welding sequence; During welding, the circumferential fillet welds are welded by argon arc welding, the plug welding holes are welded by argon arc welding, the gap between the outermost support ring (202) and the inner wall of the cylinder (101) is filled, the deformation during the backing welding is prevented, and then the φ3.2 electrode arc welding is adopted to control the welding heat input and the deformation. In the process of welding, follow the sequence of simultaneous operation of multiple people, one layer of each plug welding hole, 12 plug welding holes take 4 people symmetrically at the same time welding operation, first weld four plug welding hole one (1) one layer, then weld another four plug welding hole two (2) one layer, then weld the last four plug welding hole three (3) one layer, then weld the second layer of plug welding hole one (1), the second layer of plug welding hole two (2), the second layer of plug welding hole three (3), then weld the third layer of plug welding hole one (1); S7. The threaded holes (207) on the outermost support ring (202) are drilled using an in-house drilling template (201), and the threaded holes (207) are only 19 mm away from the inner wall of the cylinder (101). Because the diameter of the drill chuck is relatively large, conventional drilling machines cannot drill close to the inner wall, so a bevel gear right-angle inverter is used for drilling.

2. The process for manufacturing a gas phase reactor distributor according to claim 1, characterized in that, In step S1, the diameter of the cylinder (101) is controlled to be 2 mm larger than the required size on the drawing when it is formed. When the cylinder steel plate is cut, the length in the plate length direction is controlled to be 6 mm larger than the required size on the drawing.

3. The process for manufacturing a gas phase reactor distributor according to claim 1, wherein, In step S3, the thickness of the outermost support ring (202) steel plate is increased by 5 mm when it is cut; when the outermost support ring (202) is coiled, the inner diameter is formed by subtracting 4 mm from the theoretical value.

4. The process for manufacturing a gas phase reactor distributor according to claim 1, wherein, In step S7, the bevel gear right-angle inverter is a small bevel gear box right-angle inverter with a speed ratio of 1:

1.

5. A gas phase reactor distributor characterized in that, Prepared by the manufacturing process of any one of claims 1-4. Prepared by the manufacturing process of any one of claims 1-4.

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