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How to follow up the large-scale compressor manufacturers of petrochemical plants
Large-scale petrochemical plants have significantly boosted the production of essential equipment such as pumps, valves, and compressors. Among these, compressors play a critical role in the industry. Although China's compressor sector has made notable progress through technology introduction, absorption, and innovation, it still lags behind global leaders in terms of performance, reliability, and efficiency. As the petrochemical industry continues to expand with larger and more complex facilities, the question arises: how can China’s compressor industry catch up and reach international standards?
In recent years, both domestically and globally, the scale of petrochemical production has grown substantially, leading to a clear trend toward larger compressors. Internationally, for instance, atmospheric and vacuum distillation units have reached 17 million tons per year, catalytic cracking units up to 6.5 million tons, continuous reforming units up to 2.45 million tons, and hydrocracking units up to 3.5 million tons annually. Delayed coking units now process 6.4 million tons yearly, while ethylene cracking units reach 1.27 million tons, and polyethylene and polypropylene plants operate at 500,000 tons per year.
Despite progress in China’s compressor industry, foreign manufacturers still dominate the market. Although domestic companies have started to challenge this monopoly, there remains a gap in technical capabilities, manufacturing processes, and management levels. As a result, about 30% of centrifugal compressors and 20% of reciprocating compressors are still imported, particularly for high-pressure applications.
The most commonly imported compressors include reciprocating ultrahigh-pressure, labyrinth, and diaphragm compressors used in large-scale ethylene "triple machines," polypropylene, and polyethylene plants. Additionally, screw compressors in olefin extraction plants and air compressors in PTA (purified terephthalic acid) plants are difficult to design and manufacture locally. The PTA air compressor unit, for example, is driven by a steam turbine and also powers a generator and exhaust turbine, making it highly complex.
Since the early 2000s, the scale of domestic refineries has increased from 2.5 to 5 million tons per year to current capacities of 8 to 10 million tons. Similarly, ethylene plant sizes have expanded from 110,000 to 300,000 tons per year to 800,000 to 1 million tons. The largest petrochemical centrifugal compressor currently in operation in China is the crack gas compressor in Shanghai Seker’s 900,000-ton ethylene cracker, with an inlet flow of 260,000 Nm³/h, an outlet pressure of 3.89 MPa, and a shaft power of 45,000 kW. The largest reciprocating compressor is an ultrahigh-pressure unit in a 200,000-ton/year high-pressure polyethylene plant, with a mass flow of 85,000 kg/h, an outlet pressure of 310 MPa, and a power of 16,500 kW.
Research and development in the compressor industry is shifting toward improving reliability, energy efficiency, and integration with electrical systems. Advances in three-dimensional flow theory have enhanced impeller and diffuser designs, increasing compressor efficiency beyond 88%. Modern control systems ensure stable operation for over three years without shutdowns.
In product design, thermodynamics and dynamics software, along with simulation tools, help predict real-world performance and improve new product development success rates. Electromechanical integration enables automated monitoring, optimization, and protection, enhancing operational safety and efficiency. Compressor designs now emphasize aesthetics and environmental compliance, meeting stricter ecological standards.
Reciprocating compressors, widely used in oil refining, ethylene, and fertilizer industries, have seen significant improvements. Their maximum piston load exceeds 1,250 kN, and shaft power surpasses 10,000 kW. These compressors are evolving toward larger capacity, higher pressure, compact design, low energy consumption, reduced noise, and improved exhaust purification.
Screw compressors are popular due to their small size, light weight, and ease of maintenance, but they remain largely imported due to high flow, pressure, and power demands. Examples include butadiene screw compressors in ethylene plants and regenerated gas screw compressors in polyethylene plants. Globally, screw compressor technology is rapidly advancing, with new tooth profiles improving efficiency and structural innovations enhancing performance. Microprocessor-based control systems now enable automatic monitoring, protection, and integration with electromechanical systems.