Key Manufacturing Technologies for Ultra-large Hydrogenation Reactors

JIANG Wenchun; ZHAO Chunhui; WANG Jinguang; DONG Wangping; YUAN Jijun; PAN Xiaodong; LEI Chenglong; TU Shandong

doi:10.27022/j.issn2097-7697.2026.01.003

Journal of Special Equipment ›› 2026, Vol. 1 ›› Issue (1) : 22-35. DOI: 10.27022/j.issn2097-7697.2026.01.003

Advanced Manufacturing

Key Manufacturing Technologies for Ultra-large Hydrogenation Reactors

JIANG Wenchun¹, ZHAO Chunhui¹, WANG Jinguang², DONG Wangping², YUAN Jijun³, PAN Xiaodong⁴, LEI Chenglong⁵, TU Shandong⁶

Author information +

History +

Abstract

Hydrogenation reactors are the core equipment for the integrated refining and petrochemical operations and are crucial to safeguarding national energy security. With the petrochemical industry evolving towards large-scale of “10-million-ton” refining capacities, hydrogenation reactors are exhibiting a significant trend towards ultra-large diameters and ultra-large wall thicknesses. As a consequence, ensuring the intrinsic safety of the equipment while achieving lightweighting design becomes a key challenge for the industry. This paper comprehensively reviews the development of China’s hydrogenation reactor from the import dependence, through independent innovation, to achieving global leadership. Then, the integrated construction system satisfying the extreme-dimensional manufacturing demand is introduced, which is guided by advanced structural design, centered on efficient and high-quality manufacturing and precise residual stress control, and safeguarded by full-coverage non-destructive testing. Based on this system, China successfully developed the world’s first 2 000-ton class coal liquefaction reactor and the 3 000-ton class slurry bed reactor. As a result, the conversion rate of residual oil has increased from 30% to 95% and the batch production of extra-large hydrogenation reactors has been achieved and reliably deployed in multiple million-ton-class facilities. These accomplishments firmly marked China’s construction technology for ultra-large hydrogenation reactors has reached an internationally leading level.

Key words

Ultra-large hydrogenation reactors / Design / Fabrication / Inspection

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

JIANG Wenchun, ZHAO Chunhui, WANG Jinguang, DONG Wangping, YUAN Jijun, PAN Xiaodong, LEI Chenglong, TU Shandong. Key Manufacturing Technologies for Ultra-large Hydrogenation Reactors[J]. Journal of Special Equipment, 2026, 1(1): 22-35. https://doi.org/10.27022/j.issn2097-7697.2026.01.003

References

[1] 陈学东,范志超,陈永东,等.我国高端压力容器设计制造与维护技术进展[J].机械工程学报,2023,59(20):18-33.
[2] CJEM X D, FAN Z C, DONG J, et al. Technical progress review and prospect of safety guarantee for long-term service hydrogenation reactors[C/OL]//Volume 1: Codes and Standards. Virtual, Online: American Society of Mechanical Engineers, 2021: V001T01A054. https://asmedigitalcollection.asme.org/PVP/proceedings/PVP2021/85314/V001T01A054/1121940.
[3] 张春义,朱戈,田志勇,等.加氢反应器接管法兰密封槽失效原因分析及改进措施[J].中国安全科学学报,2024,34(12):100-107.
[4] HUANG S, LI Y, SONG X Y, et al.Experimental and numerical investigation on manufacturing-induced material inhomogeneity in hydrogenation reactor shell[J]. Journal of Pressure Vessel Technology, 2020,142(5):051 504.
[5] YUAN Y, LI D, ZHANG L N, et al.Development, status, and prospects of coal tar hydrogenation technology[J]. Energy Technology, 2016,4(11):1 338-1 348.
[6] SUN R J, SHEN S G, ZHANG D F, et al.Hydrofining of coal tar light oil to produce high octane gasoline blending components over γ-Al₂O₃- and η-Al₂O₃-supported catalysts[J]. Energy & Fuels, 2015, 29(11):7 005-7 013.
[7] DUAN X N, YIN J B, FENG A X, et al.Continuous hydrogenation of halogenated nitroaromatic compounds in a micropacked bed reactor[J]. Journal of Flow Chemistry, 2022,12(1):121-129.
[8] HERACLEOUS E, PAPADOPOULOU F, LAPPAS A.Continuous slurry hydrotreating of sewage sludge-derived hydrothermal liquefaction biocrude on pilot-scale: Comparison with fixed-bed reactor operation[J]. Fuel Processing Technology, 2024, 253:108 006.
[9] 张银顺. 加氢反应器的设计[J].石化技术,2017,24(9):41-42.
[10] 夏益亮,赵清万,张超.板-锻复合结构加氢反应器的研制[J].中国化工装备,2019,21(2):13-19.
[11] 李伟,边境,王学东,等.加氢反应器用不锈钢带极堆焊焊剂的研制[J].电焊机,2021,51(10): 37-42.
[12] 柳曾典,陈进,卜华全,等.2.25Cr-1Mo-0.25V钢加氢反应器开发与制造中的一些问题[J].压力容器,2011,28(5):33-40.
[13] 吴宗烈. 加氢反应器的国产化[J].压力容器,1991(2):22-25.
[14] 邝小娟,贾金廷,邹伟,等.浆态床加氢反应器整体吊装技术[J].施工技术(中英文),2024,53(14):82-87.
[15] CHEN X D, FAN Z C, CHEN Y D, et al.Development of lightweight design and manufacture of heavy-duty pressure vessels in China[C]//ASME 2018 Pressure Vessels and Piping Conference. Prague, Czech Republic: ASME, 2018: 84 176.
[16] 涂善东,王润梓,温建锋.高温机械强度若干前沿探索与展望[J].机械强度,2025,47(9):1-37.
[17] 陈学东,范志超,陈永东,等.我国压力容器设计制造与维护的绿色化与智能化[J].压力容器,2017,34(11):12-27.
[18] 李立权,陈崇刚.加氢装置大型化进展[J].炼油技术与工程,2019,49(3):1-9.
[19] 刘农基,聂颍新,陈崇刚,等.广西石化渣油加氢反应器轻量化设计制造[J].压力容器,2015,32(1):25-35.
[20] 万里平,李宇.考虑蠕变作用的2.25Cr-1Mo-V钢加氢反应器设计方法[J].压力容器,2021,38(12):62-69.
[21] 王云,黄志影.2.25Cr-1Mo-V钢制反应器蠕变-疲劳寿命分析[J].一重技术,2017(6):1-6.
[22] 中国石油大学(华东),中国石化工程建设有限公司.一种考虑焊接残余应力的焊接接头蠕变疲劳寿命评定方法:CN202210490978.5[P].2024-10-11.
[23] 刘自立. 加氢反应器用2.25Cr-1Mo钢铌钒微合金化及其碳化物析出行为[D].沈阳:东北大学,2020.
[24] HE M, ONWUDINANTI C, ZHENG Y T, et al.Ab initio study of metal carbide hydrides in the 2.25Cr1Mo0.25V steel[J]. Physical Chemistry Chemical Physics, 2021, 23(9): 5 199-5 206.
[25] 杨雪倩,曾妍,曾田田,等.临氢设备用2.25Cr-1Mo-0.25V钢及其焊材的研究现状[J].化工设备与管道,2020,57(6):27-31.
[26] 陈学东,范志超,崔军,等.我国压力容器高性能制造技术进展[J].压力容器,2021,38(10):1-15.
[27] 李宇. 加氢反应器冷氢入口结构设计与改进[J].炼油技术与工程,2024,54(6):22-25.
[28] 董岚枫,钟约先,马庆贤,等.大型筒体锻件的成形制造技术[J].锻压技术,2007(3):1-6.
[29] 廖巨智,宋忠臣.热壁加氢反应器的制造[J].炼油设计,1991,21(5):45-48.
[30] 杨华,潘强,陈广军,等.12Cr2Mo1R厚壁筒体加氢反应器锻件工艺研究[J].石油工业技术监督,2019,35(11):18-21.
[31] 赵建华,陈明,刘晓丽,等.加氢反应器大型筒体锻造工艺优化[J].大型铸锻件,2015(4):39-40.
[32] 王玉台. 加氢反应器制造技术的新进展[J].石油化工设备技术,2006(5):8-9.
[33] 周岩,刘凯泉,展培培.超大型加氢反应器过渡段筒体绿色制造技术[J].锻造与冲压,2020(7):43-47.
[34] 天津重型装备工程研究有限公司,中国第一重型机械股份公司.一种加氢反应器过渡段与筒体一体化锻造方法:CN201910600707.9[P].2020-11-06.
[35] AGHAAHMADI M, KIM W H, LEE H, et al.Optimization of 75 mm ultra-thick Ti-6Al-4V alloy plates for aerospace applications: microstructure and mechanical properties analysis[J]. Materials Transactions, 2025,66(5):590-599.
[36] BUTLER C A, MEISTER R P, RANDALL M D.Narrow gap welding[J]. Welding Journal, 1969,48(2):102-108.
[37] 吴叶军,王加友.窄间隙GMAW技术研究进展[J].热加工工艺,2018,47(21):7-10.
[38] 林尚扬,于丹,于静伟.压力容器焊接新技术及其应用[J].压力容器,2009,26(11):1-6.
[39] 张亚兵,张建晓,李阳,等.双丝窄间隙埋弧焊技术在厚壁加氢反应器中的应用[C]//2018年甘肃省焊接学术会议论文集.兰州:甘肃省机械工程学会.兰州理工大学,2018:354-361.
[40] 万娱,张旭阳,蒋文春,等.加氢反应器2.25Cr-1Mo-0.25V钢厚壁双丝窄间隙埋弧焊接头强韧性退化行为及机理[J].焊接学报,2025,46(5):113-120.
[41] 中国石油大学(华东).一种基于残余应力调控的大型加氢反应器内壁耐腐蚀层宽带极堆焊方法:CN201810328525.6[P].2018-08-03.
[42] 刘宝剑,孔凡红,王天先,等.国产单层带极电渣堆焊焊材在加氢反应器的应用[J].压力容器,2019,36(9):70-77.
[43] 刘宝剑,孙靖东,王毅,等.90 mm宽带极单层电渣堆焊在加氢反应器的应用[C]//中国机械工程学会压力容器分会.压力容器先进技术——第十届全国压力容器学术会议论文集(下).杭州:中国机械工程学会,2021:900-906.
[44] 中国石油大学(华东).基于焊接残余应力调控的加氢反应器凸台梯级电流堆焊法:CN202210428386.0[P].2023-05-16.
[45] 中国石油化工股份有限公司,中国石化工程建设有限公司,中国石油大学(华东).一种加氢反应器支撑台焊接方法:CN202311307090.4[P].2025-11-14.
[46] XIE W L, WAN Y C, JIANG W C, et al.Controlling method of the welding residual stress in support platform of hydrogenation reactor[J]. International Journal of Pressure Vessels and Piping, 2024, 207: 105 101.
[47] 二重集团(德阳)重型装备股份有限公司.90°弯管的内壁堆焊方法:CN201310132958.1[P].2015-03-25.
[48] 王庆伟. 加氢反应器90°弯管内壁整体不锈钢自动堆焊[J].金属加工(热加工),2016(22):41-45.
[49] 张永祥,陈宏伟,朵元才,等. 90°弯管整体堆焊技术研究与应用[J].中国化工装备,2017,19(2):8-12.
[50] 闫宏伟,谷文,高殿宝. 90°弯管先堆焊后热成形技术[J].压力容器,2014,31(7):70-73.
[51] 熊维琼,王新农,孙亚杰,等.加氢反应器的制造及监督检验技术探讨[J].中国特种设备安全,2024,40(5):82-87.
[52] 谷文斌,蒋文春,王金光,等.承压设备局部焊后热处理方法和准则研究[J].压力容器,2025,42(2):10-22.
[53] 王建军,王嘉睿.固溶和稳定化热处理对TP347钢焊接接头组织的影响研究[J].炼油技术与工程,2024,54(1):22-26.
[54] 郑红果,陈万申,王志刚.大型化工设备现场组焊环向焊接接头热处理装置——卡式热处理炉[J].石油化工设备,2010,39(2):33-36.
[55] LUO Y, ZHANG Y X, YANG G, et al.Reducing temperature gradient during local heat treatment process with card furnace for large-scale hydrogenation reactor[J]. Case Studies in Thermal Engineering, 2025,76:107 420.
[56] 王志刚,罗永智,秦作伟.压力容器现场焊后热处理技术应用现状及发展趋势[J].金属热处理,2022,47(9):281-285.
[57] GU W B, JIANG W C, XIE X F, et al.Evolution of temperature and residual stress of ultra-thick pressure vessel during local PWHT by electromagnetic Induction[J]. Journal of Pressure Vessel Technology, 2025, 147(6):061 502.
[58] GU W B, JIANG W C, CHEN J K, et al.A stress regulation theory on local post weld heat treatment of ultra-large pressure vessels[J]. International Journal of Pressure Vessels and Piping, 2025, 218:105 586.
[59] 蒋文春,谷文斌,金强,等.主副加热分布式热源局部热处理方法[J].焊接学报,2023,44(5):27-35.
[60] 刘德宇,沈功田,李邦宪.压力容器无损检测——加氢反应器的无损检测技术[J].无损检测,2005(2):96-99.
[61] JIANG W C, LUO Y, ZENG Q, et al.Residual stresses evolution during strip clad welding, post welding heat treatment and repair welding for a large pressure vessel[J]. International Journal of Pressure Vessels and Piping,2021,189:104 259.
[62] 彭伟,蒋文春,杨滨,等.压入能量差法测试二向残余应力[J].中国科学:物理学力学天文学,2023,53(1):8-18.
[63] SUN G H, JIANG W C, YANG B, et al.A single-cycle spherical indentation method to determine the tensile properties of materials with different hardening behaviors[J]. Measurement, 2025,249:117 026.