News Details

1、 Materials and Structural Design: Collaborative Innovation of High Strength and Wear Resistance

The core energy of the high flow APIDN200 chemical conveying hose lies in its material science breakthrough and structural optimization. The inner lining layer is made of a composite material of ultra-high molecular weight polyethylene (UHMWPE) and fluororubber (FKM). The former provides excellent wear resistance (friction coefficient as low as 0.05), while the latter ensures chemical corrosion resistance (can withstand 98% concentrated sulfuric acid and strong alkaline solutions). According to actual test data from a petrochemical enterprise, the wear rate of the composite lining when transporting corrosive slurry containing 30% quartz sand is only 0.02mm/thousand hours, which is 8 times longer than the service life of traditional nitrile rubber lining.

 

The reinforcement layer design adopts a dual safety structure of "steel wire weaving+aramid winding". The diameter of the steel wire is 0.35mm, with a weaving density of 90%, providing a bearing capacity of ≥ 16MPa for explosive pressure; Aramid fibers are cross wound at ± 55 ° to form an impact resistant buffer layer. In the testing of a catalytic cracking unit in a certain refinery, the deformation of the hose was controlled within 3% when subjected to an instantaneous pressure shock of 2MPa, and there was no structural damage. The outer sheath is made of chlorosulfonated polyethylene (CSM) rubber, and the tear resistance is increased to 45kN/m by adding nano zinc oxide filler, which can resist sharp object scratching and UV aging.

 

The carbon steel flange, as a key connecting component, is made of ASTM A105 forging material, with a surface hardness of HRC60-62 after nitriding treatment. Combined with duplex stainless steel (2205) overlay, it significantly improves corrosion resistance. The flange sealing surface adopts a trapezoidal groove+metal wrapped gasket structure. Under a pressure of 10MPa and a high temperature of 300 ℃, the leakage rate is less than 1 × 10 ⁻⁹ Pa · m ³/s, meeting the sealing requirements of API 6A standard Class 6000. The application of pipeline system in a certain chemical industrial park shows that after 2 years of continuous operation, the bolt pre tightening force attenuation rate of the flange connection is less than 5%.

 

2、 High flow conveying technology: balance optimization between high efficiency and low energy consumption

APIDN200 hose achieves high flow transportation through fluid dynamics optimization. Its inner diameter is designed to be 200mm (DN200), combined with a parabolic inner wall profile, reducing the fluid resistance coefficient to 0.018 (traditional hoses have 0.035). In a certain ethylene conveying project, when the conveying capacity reaches 1200m ³/h, the system pressure drop is reduced by 40% compared to DN150 hoses, saving about 150000 kWh of pumping energy annually. In addition, the hose adopts a segmented corrugated structure with a spacing of 150mm between each corrugated section, which ensures bending flexibility (small bending radius R=3D) and avoids uneven flow velocity distribution caused by excessive deformation.

 

In response to the demand for multiphase flow transportation in the petrochemical industry, microstructure treatment is carried out on the surface of the hose lining. By using laser etching technology to form honeycomb shaped pits (diameter 0.5mm, depth 0.1mm), the gas-liquid two-phase flow state is transformed from "plug flow" to "annular flow", and stable transportation can still be maintained even when the gas content reaches 30%. In a test on a certain offshore platform of CNOOC, this design improved the transportation efficiency of crude oil natural gas mixture by 25%, while reducing the pipe wall erosion rate by 60%.

 

To cope with extreme working conditions, the hose is equipped with an intelligent monitoring system. Embedded fiber optic sensors can monitor temperature (accuracy ± 0.5 ℃), pressure (accuracy ± 0.1MPa), and deformation (sensitivity 0.01mm) in real time, and the data is transmitted to the central control platform through 5G. During the trial operation of a certain unit in Zhenhai Refining and Chemical, the system issued a warning 3 hours in advance of the risk of local wear exceeding the limit, avoiding an unplanned shutdown accident.

 

3、 Petrochemical equipment adaptability: full scene coverage from refining to fine chemicals

In the refining unit, APIDN200 hoses need to withstand high temperature, high pressure, and strong corrosive media. A 10 million ton refinery's atmospheric and vacuum distillation unit uses this hose to connect the vacuum tower and heat exchanger. When transporting 380 ℃ high-temperature residual oil, the outer temperature of the hose is controlled within 60 ℃ to ensure the safety of operators. The matching carbon steel flange is treated with nickel phosphorus alloy on the surface, and the corrosion rate is less than 0.01mm/year in an environment with a H ₂ S concentration of 500ppm, meeting the maintenance free requirement for continuous operation for 5 years.

 

The fine chemical industry has strict requirements for the cleanliness of hoses. A pharmaceutical intermediate production enterprise adopts inner lining polishing technology (Ra ≤ 0.4 μ m), combined with CIP online cleaning system, to make the residue on the inner wall of the hose ≤ 0.5mg/m ², in compliance with FDA 21 CFR 177.2600 standard. When switching between consecutive production batches, the cleaning time has been reduced from 4 hours using traditional methods to 1.5 hours, resulting in a 15% increase in production capacity.

 

For the transportation of hazardous chemicals, the hose is designed with multiple safety protections. The outer sheath is coated with flame retardant (oxygen index ≥ 32%) and has passed UL94 V-0 certification; Built in anti-static guide wire (resistance<10 ⁶ Ω) ensures timely dissipation of static electricity generated by medium friction. In an emergency drill at a hazardous chemical storage base, the hose withstood 30 minutes of flame roasting without structural failure during a simulated toluene leakage accident, which saved critical time for emergency response.

 

4、 Quality Control and Future Trends: Digital Management of the Whole Life Cycle

The production of APIDN200 hoses follows the dual system certification of ISO 9001 and API Q1. From raw materials to finished products, 12 testing processes are required, including:

 

Raw material testing: Rubber Mooney viscosity (ML1+4 @ 100 ℃) fluctuation range ± 2, steel wire tensile strength ≥ 1870MPa;

Process monitoring: Real time recording of vulcanization temperature ± 1 ℃, pressure ± 0.1MPa, weaving angle deviation ≤ ± 1 °;

Finished product testing: Burst pressure ≥ 24MPa (1.5 times the design pressure), pulse fatigue life ≥ 500000 times (pressure cycle 0-12MPa).

The digital traceability system realizes full lifecycle management. Each hose is equipped with an RFID chip, which stores over 200 data items such as production batches, inspection reports, installation locations, etc. In the application of a certain petrochemical group, the system increased inventory turnover by 40% and reduced fault location time from an average of 72 hours to 2 hours.

 

In the future, hose technology will develop towards intelligence and greenness. Research directions include:

 

Self repairing material: embedded with microcapsule repair agent, automatically filled when microcracks occur;

Lightweight design: using carbon fiber reinforced composite materials, reducing weight by 30% without compromising strength;

Energy recovery: Integrating piezoelectric materials on the outer layer of the hose to convert fluid pressure energy into electrical energy.

conclusion

The high flow APIDN200 chemical conveying hose carbon steel flange wear-resistant petrochemical equipment pipe has constructed a technical system that adapts to complex working conditions in the petrochemical industry through material innovation, structural optimization, and intelligent integration. From the high temperature and high pressure of refining equipment to the cleanliness requirements of fine chemicals, from the safety guarantee of hazardous chemical transportation to the digital management of the entire life cycle, its performance has verified the deep integration of API standards and domestic technology. In the future, with the advancement of the "dual carbon" target and the upgrading of intelligent manufacturing, such products will play a more critical role in the construction of green chemicals and smart factories.