News Details

1、 Materials and Structural Design: Collaborative Innovation of Corrosion Resistance and Explosion proof Performance

The core competitiveness of the corrosion-resistant APIDN100 storage and transportation hose lies in the deep integration of its corrosion-resistant materials and explosion-proof reinforcement structure. The inner lining layer adopts a composite material of fluorosilicone rubber (FVMQ) and perfluoroethylene propylene (FEP). The fluorosilicone rubber provides excellent chemical resistance (can withstand 98% sulfuric acid, 30% sodium hydroxide, and benzene organic solvents), and the FEP coating reduces the friction coefficient of the medium contact surface to 0.03, significantly reducing fluid erosion of the pipe wall. Laboratory tests have shown that the liner has a mass change rate of ≤ 0.8% and a volume swelling rate of ≤ 2% when transporting crude oil containing 5% hydrogen sulfide, and there is no cracking phenomenon after continuous operation at 120 ℃ for 2000 hours.

 

The reinforcement layer adopts a composite structure of "high carbon steel wire weaving+stainless steel spiral winding". High carbon steel wire (diameter 0.5mm, tensile strength ≥ 2200MPa) is woven in double layers (weaving density 85%) to form the main skeleton and withstand a burst pressure of ≥ 12MPa; Stainless steel spiral winding layer (316L material, pitch 12mm) serves as secondary reinforcement to resist external sharp object impact and internal pressure fluctuations. In a test conducted at a certain refinery, the deformation of the hose was controlled within 1.5% when subjected to a transient pressure impact of 8MPa, and there was no structural damage. The outer sheath is made of chlorosulfonated polyethylene (CSM) and carbon fiber composite material. By adding nano zirconia (ZrO ₂) wear-resistant particles, the Akron wear is reduced to 0.03cm ³/1.61km, and the ozone aging resistance (50pphm, 40 ℃× 72h) reaches zero crack standard.

 

The explosion-proof joint design has passed API 6D and ATEX certification, using carbon steel forged flanges (ASTM A105), nickel phosphorus alloy plating on the surface (thickness ≥ 15 μ m), and is matched with conductive rubber sealing rings and grounding copper braided tape (cross-sectional area ≥ 25mm ²) to achieve equipotential connection between hoses and pipeline systems. In the application of a certain ethylene plant, the static potential difference of the joint during continuous transportation of flammable media is always less than 30V, far below the 60V threshold required by GB 50058 standard, and the grounding resistance is ≤ 0.05 Ω, effectively preventing the risk of explosion caused by static sparks.

 

2、 Refinery full scenario adaptation: customized solution from raw material transportation to finished product storage and transportation

1. Strong corrosion and high pressure challenges in raw material transportation

In the crude oil pretreatment section, DN100 hoses need to withstand corrosion from high sulfur crude oil (sulfur content of 3% -5%) and acidic media. The surface of the hose lining is treated with laser microstructure (groove depth of 0.2mm, width of 0.5mm) to form a turbulence promoting layer and reduce the risk of medium deposition. The matching explosion-proof joint is equipped with a ceramic liner (hardness HRA92), which can resist direct erosion from hard particles in crude oil. In the application of a certain unit in Zhenhai Refining and Chemical, this design extends the service life of the hose from 8 months of traditional products to 36 months, and reduces the annual replacement cost by 70%.

 

2. High temperature and fatigue resistance requirements for catalytic cracking units

In response to the high temperature oil and gas (temperature 350-450 ℃) and pressure fluctuations (0-6MPa) in the catalytic cracking unit, the steel wire of the hose reinforcement layer is treated with aluminum infiltration (aluminum layer thickness ≥ 10 μ m) to form a dense alumina protective film, which increases the high-temperature oxidation resistance by three times. At the same time, the hose adopts a segmented corrugated structure (with a corrugated spacing of 150mm) and a small bending radius of R=4D, which can adapt to complex pipeline layouts inside the device. In the testing of a catalytic cracking unit at Maoming Petrochemical, the hose showed no carbonization of the inner lining or cracking of the outer layer after continuous operation for 18 months, and the operational stability was improved by 50%.

 

3. Low temperature and explosion-proof safety in finished product storage and transportation

In the finished oil storage tank area, hoses need to deal with the dual challenges of low-temperature diesel (condensation point -10 ℃) and flammable vapors. Add phase change energy storage material (paraffin based PCM, phase change temperature 5-15 ℃) to the outer sheath to reduce the surface temperature fluctuation range of the hose to ± 3 ℃ and suppress low-temperature embrittlement. At the same time, the hose is equipped with built-in fiber optic sensors that can monitor temperature (accuracy ± 0.2 ℃), pressure (accuracy ± 0.01MPa), and leakage (sensitivity 0.1mL/min) in real time, and the data is wirelessly transmitted to the central control room through LoRa. In an emergency drill in a storage tank area of Yanshan Petrochemical, the system warned of local leakage risks one hour in advance, avoiding a major safety accident.

 

3、 Quality control and intelligent upgrade: full lifecycle digital management

1. Strict production testing system

The production of APIDN100 hoses follows the dual system standards of API Q1 and ISO 9001, and 22 testing processes are required from raw materials to finished products:

 

Raw material testing: Fluorosilicone rubber Mooney viscosity (ML1)+ 10@121 The fluctuation range is ± 1.5 ℃, and the tensile strength of the steel wire is ≥ 2200MPa;

Process monitoring: Real time recording of vulcanization temperature ± 0.3 ℃, pressure ± 0.01MPa, weaving angle deviation ≤ ± 0.4 °;

Finished product testing: burst pressure ≥ 18MPa (1.5 times the design pressure), pulse fatigue life ≥ 1.2 million times (pressure cycle 0-10MPa), low-temperature brittleness (-50 ℃ without cracks).

2. Digital traceability and predictive maintenance

Each hose is equipped with an RFID chip and QR code, storing over 600 data items such as production batches, inspection reports, installation locations, etc. In the practice of a unit at Hengli Petrochemical, the system increased inventory turnover by 65% and reduced fault location time from an average of 72 hours to 1.5 hours. At the same time, the MEMS sensors embedded in the hose can monitor vibration (frequency range 0-2kHz), acceleration (± 100g), and displacement (accuracy ± 0.05mm), predict remaining life through deep learning algorithms, and improve maintenance plan accuracy by 80%.

 

3. Trends in Green and Intelligent Technologies

In the future, hose technology will evolve in the following directions:

 

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

Lightweight design: using titanium alloy skeleton and carbon fiber reinforced composite material, reducing weight by 25% without compromising strength;

Energy self-sufficiency: Integrating flexible solar films on the outer layer of the hose to power sensors and communication modules, reducing energy consumption in the refinery.

4、 Industry Application Case: Practical Verification from Refining to Chemical Industry

Refining unit: A certain atmospheric and vacuum distillation unit of Sinopec Jinling Petrochemical uses DN100 hoses to transport high-temperature residual oil (temperature 420 ℃), with steel reinforced structure and high-temperature resistant lining to achieve zero leakage operation, increasing single line production capacity by 15%.

Chemical unit: A MDI unit of Wanhua Chemical uses this hose to transport phosgene (highly toxic medium), and the explosion-proof joint and real-time monitoring system ensure operational safety. After 2 years of continuous operation, no leakage incidents have occurred.

Dock loading and unloading: A crude oil terminal at Ningbo Port used this hose to cope with high flow velocity (6m/s) and strong impact conditions during the unloading operation of a very large crude oil tanker (VLCC). The lining showed excellent wear resistance and steel braided torsion resistance, and the loading and unloading efficiency increased by 20%.

conclusion

The corrosion-resistant APIDN100 storage and transportation hose steel braided reinforced explosion-proof refinery connecting pipeline has been constructed through material innovation, structural optimization, and intelligent integration to adapt to the complex working conditions of refineries. From the strong corrosion and high-pressure challenges of raw material transportation, to the high temperature and fatigue resistance requirements of catalytic cracking units, to the low temperature and explosion-proof safety of finished product storage and transportation, its performance has verified the deep integration of API standards and domestic technology. In the future, as the refining industry evolves towards large-scale, intelligent, and green development, such products will play a more critical role in improving production efficiency, reducing safety risks, and ensuring energy supply, driving the petrochemical equipment industry to a higher level.