催化剂项目的输送难点，往往不在单台旋转阀，而在拆包口、上料点、输送管线和计量单元之间的接口。上海科全在中石化上海催化剂研究中心项目中承担的，就是这样一条整线：从拆包、上料、气力输送一直到计量，由同一家完成工艺接口、设备成套与现场调试。
一、项目档案：四个单元，一条整线
| 项目名称 | 中石化上海催化剂研究中心整线气力输送项目 |
|---|---|
| 项目地点 | 上海 |
| 供货范围 | 拆包、上料、气力输送、计量四个单元 |
| 服务内容 | 工艺接口、设备成套、现场调试与验收配合 |
| 物料类型 | 催化剂粉体 |
这类项目的采购边界，如果只买到一台旋转阀或一段管道，现场很容易出现“阀选对了、上料不顺”“输送通了、计量漂移”的接口问题。整线由一个供应商负责，责任边界才能落到同一条工艺链上。
二、四个单元分别解决什么问题
| 单元 | 在本项目中的任务 | 必须提前确认的接口 |
|---|---|---|
| 拆包 | 完成催化剂原料的密闭拆包与投料，控制扬尘、洒落和外界湿气进入 | 拆包口与上料入口的密封形式、除尘接口、操作高度 |
| 上料 | 把拆包后的物料稳定送入输送系统，匹配输送节拍，避免架桥和冲料 | 上料点与供料设备的料位、破拱方式、启停联锁 |
| 气力输送 | 按物料特性与布置条件确定稀相、中间相或密相，完成管道、阀件、分离与排气 | 输送入口与计量仓之间的压差、气速、料位和背压 |
| 计量 | 按工艺配方完成称重或连续喂料，并把计量数据反馈到整线控制 | 计量信号与上料、输送的启停联锁，补料冲击的隔离 |
把这四段拆开看，每一段都不复杂；难的是四段之间的边界。整线集成的价值，就是把这些边界在图纸阶段一次确认，而不是等到现场再补。
项目现场：拆包、上料与输送末端
项目现场配置了小袋拆包上料机、吨包站，以及气力输送末端的接料斗与固气分离一体化中间料斗，分别对应小袋来料、吨包来料和输送末端接料。设备规格与接口以项目技术协议为准。
Small-bag unpacking and feeding station: bag opening and feed interface
Jumbo-bag (FIBC) station: discharge and feed interface
Receiving hopper with integrated gas–solid separation: line-end receiving, separation and buffering
三、催化剂粉体为什么更考验整线能力
催化剂粉体通常粒径细、堆密度低、易扬尘，部分牌号还具有磨蚀性、易吸湿或易粘壁的特点。物料特性会同时影响四个单元：
- 拆包段：细粉扬尘大，拆包口必须做密闭和负压捕集，否则现场环境与物料损失都不可控；
- 上料段：低堆密度粉体容易架桥、粘壁，上料结构要避免死角，并给破拱和助流留出接口；
- 输送段：气速过高会带来破碎、磨损和静电，气速过低又会积料堵管，需要先判相态再定气速；
- 计量段：补料冲击、气流脉动和料位波动都会进入称重信号，计量单元必须与输送节拍联动。
四、整线集成的四个控制点
1. 先定物料，再定相态
同一套“气力输送系统”，用在催化剂细粉和塑料粒料上，方案会完全不同。整线设计的第一步不是选阀，而是确认粒径分布、堆密度、流动性、磨蚀性、含水率和允许破碎率，再据此判断稀相、中间相或密相。相态定错，后面的阀件、管道和计量都只能被动修补。
2. 接口尺寸链一次确认
拆包口的高度、上料机的进出口、输送管道的第一段走向、计量仓的入口位置，构成一条尺寸链。整线项目要在设计阶段把这条链一次确认，包括法兰标准、软连接、检修空间和清洗通道。否则现场常见的“差 50 毫米装不上”，会把整线工期拖成单点改造。
3. 计量与输送联锁
计量不是孤立的秤。上料启动、输送补料、料仓料位和称重读数之间要有明确的联锁逻辑：补料时隔离称重冲击，低料位时提前触发补料，超差时停线并记录批次。整线控制把这些信号放在同一套逻辑里，才能让计量精度在连续运行中保持住。
4. 清洗与换品种
催化剂研究中心往往多品种、小批量。拆包口、上料机、输送管道和计量仓都要考虑残留物料如何清理、不同牌号之间如何隔离。快拆结构、吹扫接口和可排空设计，应该在整线方案里一次做进去，而不是后期加装。
五、交付与验收：整线按两级节点核对
整线项目按 FAT 与 SAT 两级节点核对。FAT 阶段检查设备、阀件、控制逻辑和接口尺寸；SAT 阶段在现场检查气密性、输送稳定性、计量重复性和联锁动作。验收记录按单元归档，出现问题时能直接定位到拆包、上料、输送或计量中的具体一段。
Factory acceptance test (FAT) in Shanghai: equipment appearance, interfaces and dimensions
对技改、扩能和多品种切换项目，上海科全可参与设计联络、出具设备数据表、配合 PID 与布置图，并按 FAT 与 SAT 节点提供验收支持。项目前期可提供工况参数表模板、选型计算书、接口尺寸链确认图和分项设备清单。
六、同类工况的复用范围
这条整线的工程方法，可复用到石化催化剂、精细化工粉体、新能源材料、食品与医药粉体等场景。共同点是物料价值高、对污染和残留敏感、单元之间接口多。判断一个供应商是否适合做整线，不要只看单台设备参数，要看他能不能把拆包、上料、输送和计量四段的接口讲清楚。
七、项目信息公开边界
本文只披露项目范围与工程方法，不披露催化剂配方、产能、工艺参数和客户内部布置。具体设备参数以项目技术协议为准。
相关阅读：气力输送系统总览（稀相 / 密相 / 中间相）｜上海石化化工气力输送系统旋转阀选型指导
上海科全工程技术有限公司
注册地址：上海市松江区石湖荡镇塔汇路609号
公司地址：上海市松江区广富林路658弄4号楼705室
电话：021-6789 3550｜手机：189 1661 6687
官网：www.shconque.com
English Version: Turnkey Pneumatic Conveying for a Sinopec Catalyst Research Center — Unpacking, Feeding, Conveying and Metering in One Line
In catalyst projects, the hard part is rarely a single rotary valve. It is the interfaces between the unpacking opening, the feeding point, the conveying line and the metering unit. For the Sinopec Shanghai Catalyst Research Center, Shanghai Conque supplied exactly such a line: unpacking, feeding, pneumatic conveying and metering, with process interfaces, equipment supply and on-site commissioning handled by one supplier.
1. Project File: Four Units, One Line
| Project | Sinopec Shanghai Catalyst Research Center — turnkey pneumatic conveying line |
|---|---|
| Location | Shanghai, China |
| Scope of supply | Four units: unpacking, feeding, pneumatic conveying, metering |
| Services | Process interface, equipment package, on-site commissioning and acceptance support |
| Material | Catalyst powder |
When the purchasing boundary covers only a rotary valve or a section of pipe, the site often ends up with interface problems: the valve is right but feeding is unstable, or conveying works but metering drifts. With one supplier responsible for the whole line, accountability follows a single process chain.
2. What Each of the Four Units Solves
| Unit | Task on this project | Interfaces to confirm in advance |
|---|---|---|
| Unpacking | Dust-tight opening and dosing of catalyst raw material, controlling dust, spillage and moisture ingress | Sealing between the opening and the feed inlet, dust-extraction connection, operating height |
| Feeding | Deliver unpacked material into the conveying system at a stable rate, matching the conveying cycle and avoiding bridging and flushing | Level at the feed point, arch-breaking method, start/stop interlock with the feeder |
| Pneumatic conveying | Select dilute, intermediate or dense phase according to material and layout; complete piping, valves, separation and venting | Differential pressure, gas velocity, level and back pressure between the conveying inlet and the metering silo |
| Metering | Weighing or continuous feeding to recipe, with data fed back to line control | Interlock between metering signals and feeding/conveying start-stop; isolation of refill impact |
Taken separately, none of the four sections is complex. The difficulty lies in the boundaries between them. The value of line integration is confirming those boundaries at the drawing stage instead of patching them on site.
Project site: unpacking, feeding and the receiving end
The site is equipped with a small-bag unpacking and feeding station, a jumbo-bag (FIBC) station, and a receiving hopper with integrated gas–solid separation at the end of the conveying line, covering small-bag intake, jumbo-bag intake and line-end receiving respectively. Equipment specifications and interfaces follow the project technical agreement.
3. Why Catalyst Powder Is Harder on a Whole Line
Catalyst powders are typically fine, low in bulk density and prone to dusting. Some grades are abrasive, hygroscopic or prone to wall build-up. These properties affect all four units at once:
- Unpacking. Fine dust demands a sealed opening with negative-pressure capture; otherwise both the working environment and material losses are uncontrolled.
- Feeding. Low-bulk-density powder bridges and sticks easily. The feeding structure must avoid dead corners and provide connections for arch breaking and flow aid.
- Conveying. Too high a gas velocity causes attrition, wear and static; too low a velocity causes accumulation and blockage. Phase behaviour must be established before setting velocity.
- Metering. Refill impact, air pulsation and level fluctuation all enter the weight signal. The metering unit must be interlocked with the conveying cycle.
4. Four Control Points in Line Integration
1. Material first, then phase
Applied to catalyst fines and to plastic pellets, the same "pneumatic conveying system" becomes a completely different design. The first step is not valve selection but confirming particle size distribution, bulk density, flowability, abrasiveness, moisture content and allowable attrition, then deciding on dilute, intermediate or dense phase. Choose the wrong phase and every valve, pipe and meter downstream is only a patch.
2. Confirm the dimensional chain once
The height of the unpacking opening, the inlet and outlet of the feeder, the first run of the conveying pipe and the inlet position of the metering silo form a dimensional chain. A turnkey project must confirm that chain at the design stage, including flange standards, flexible connections, maintenance space and cleaning access. Otherwise the familiar "50 mm short and it will not fit" turns the schedule into a series of site modifications.
3. Interlock metering and conveying
A scale is not an isolated device. Start-up of feeding, refill during conveying, silo level and weight readings need explicit interlock logic: isolate the weighing impact during refill, trigger refill early at low level, and stop the line with a batch record when the deviation exceeds the limit. Only when these signals sit in one control logic can metering accuracy hold over continuous operation.
4. Cleaning and product changeover
Catalyst research centres usually run many grades in small batches. The unpacking opening, feeder, conveying pipe and metering silo must all consider how residual material is cleaned and how grades are isolated. Quick-release construction, purge connections and drainable design belong in the line concept from the start, not as later add-ons.
5. Delivery and Acceptance: A Two-Stage Check
Line projects are checked at two stages, FAT and SAT. FAT covers equipment, valves, control logic and interface dimensions; SAT covers tightness, conveying stability, metering repeatability and interlock behaviour on site. Acceptance records are filed by unit, so any issue can be traced directly to unpacking, feeding, conveying or metering.
For revamps, capacity upgrades and multi-grade changeover projects, Shanghai Conque can join design reviews, issue equipment data sheets, support P&ID and layout development, and provide acceptance support at the FAT and SAT stages. At the front end we can provide a process data sheet template, selection calculations, an interface dimensional-chain confirmation drawing and an itemised equipment list.
6. Where the Same Approach Applies
The engineering method used on this line transfers to petrochemical catalysts, fine chemicals, new-energy materials, food and pharmaceutical powders. The common factors are high material value, sensitivity to contamination and residue, and many interfaces between units. To judge whether a supplier can handle a whole line, do not look only at single-machine data. Ask whether they can explain the interfaces between unpacking, feeding, conveying and metering.
7. Disclosure Boundary
This article discloses the project scope and engineering method only. Catalyst formulations, capacity, process parameters and the customer's internal layout are not disclosed. Equipment data follow the project technical agreement.
Related reading: Pneumatic Conveying Systems Overview (Dilute / Dense / Intermediate Phase) | Rotary Valve Selection for a Shanghai Petrochemical Pneumatic Conveying System
Shanghai Conque Engineering Technology Co., Ltd.
Registered address: No. 609 Tahui Road, Shihudang Town, Songjiang District, Shanghai
Office: Room 705, Building 4, Lane 658 Guangfulin Road, Songjiang District, Shanghai
Tel: +86 21 6789 3550 | Mobile: +86 189 1661 6687
Website: www.shconque.com
