高压旋转阀在40万吨PE项目密相输送中的应用
——上海科全GVH系列高压旋转阀替代德国进口旋转阀、服务俄罗斯大型PE项目案例——Shanghai Conque GVH Series High-Pressure Rotary Valve Replacing German-Imported Rotary Valves in a Large-Scale Russian PE Project【摘要】 本文介绍了上海科全工程技术有限公司自主生产的GVH系列高压旋转阀在俄罗斯大型石油公司40万吨/年PE（聚乙烯）装置密相气力输送系统中的成功应用。由于国际制裁等原因，项目原计划采购的德国进口ZVH系列高压旋转阀随后未能成功供货。上海科全凭借在稀相/密相气力输送领域深厚的技术积累与制造能力，其自主研发生产的GVH系列高压旋转阀在性能指标上达到德国同等系列产品水平，获得了业主及韩国大林工程公司（Daelim Engineering）的认可，随后实现了对德国进口旋转阀的成功替代，并于2025年顺利完成项目终交，获得业主验收认可。[Abstract] This article presents the successful application of the GVH series high-pressure rotary valves, independently developed and manufactured by Shanghai Conque Engineering Technology Co., Ltd., in the dense-phase pneumatic conveying system of a 400,000 t/y polyethylene (PE) plant owned by Russia’s largest oil company. Due to international sanctions, the originally planned German-imported ZVH series could not be delivered. Leveraging deep technical expertise and manufacturing capabilities in dilute- and dense-phase pneumatic conveying, Shanghai Conque’s GVH series achieved performance parity with the German equivalent, gained approval from the owner and Daelim Engineering, and successfully replaced the imported product. The project achieved final acceptance in 2025.一、项目概述1. Project Overview本项目为俄罗斯大型石油公司（Rosneft / 俄罗斯石油公司）旗下年产40万吨高密度聚乙烯（HDPE）装置配套的粉粒体密相气力输送系统。该项目对高压旋转阀的密封性能、耐压等级、计量精度及长期运行可靠性提出了极高要求，涉及从聚合反应出料、挤压造粒到成品均化掺混工段的全流程物料输送。This project is a dense-phase pneumatic conveying system for the powder and pellet handling of a 400,000 t/y high-density polyethylene (HDPE) plant owned by Russia’s largest oil company (Rosneft). The project demanded exceptionally high sealing performance, pressure rating, metering accuracy, and long-term reliability from the high-pressure rotary valves, covering the entire material flow from polymerization discharge, extrusion pelletizing, to finished-product homogenization and blending.项目原设计方案中，高压旋转阀指定采用德国进口ZVH系列旋转阀。然而，由于国际制裁及供应链限制，德国进口ZVH系列旋转阀的采购未能成功。在此情况下，上海科全工程技术有限公司凭借多年深耕气力输送领域的技术积淀与制造能力，其自主研发生产的GVH系列高压旋转阀通过了严格的性能审查与对比测试，成功获得业主及工程承包商认可，实现了对德国进口旋转阀的替代，并于2004年签订供货合同。In the original design, the high-pressure rotary valves were specified as the German-imported ZVH series. However, due to international sanctions and supply-chain restrictions, the procurement of the German-imported ZVH series ultimately failed. Under these circumstances, Shanghai Conque—leveraging years of technical accumulation and manufacturing capability in pneumatic conveying—saw its independently developed GVH series pass rigorous performance reviews and comparative testing, gain approval from the owner and the EPC contractor, successfully replace the German imports, and secure the supply contract in 2004.二、项目背景与技术挑战2. Project Background & Technical Challenges2.1 项目主体与合作架构2.1 Project Parties and Cooperation Framework该项目由俄罗斯大型石油公司投资建设，韩国大林工程公司（Daelim Engineering）承担工程设计与采购管理（EPC模式下的详细设计与关键设备采购）。Daelim作为韩国知名的石化工程承包商，在大型聚烯烃装置设计与建设方面拥有丰富经验，对设备选型、工艺计算及供应商资质审核执行极为严苛的标准。The project was invested in by Russia’s largest oil company. Daelim Engineering (South Korea) was responsible for engineering design and procurement management (detailed design and key equipment procurement under an EPC model). As a leading Korean petrochemical engineering contractor with extensive experience in large-scale polyolefin plant design and construction, Daelim applied extremely stringent standards for equipment selection, process calculations, and supplier qualification audits.2.2 进口替代背景与选型波折2.2 Import Substitution Background and Selection Turnaround项目前期，Daelim工艺团队按照行业惯例指定德国进口ZVH系列高压旋转阀作为密相输送系统的锁气供料核心设备。该系列产品在3.5 bar(g)高压差工况下具有成熟应用记录，是大型聚烯烃装置气力输送系统的传统优选方案。Early in the project, Daelim’s process team specified the German-imported ZVH series as the core feed-and-seal equipment for the dense-phase conveying system, following industry convention. The ZVH series had a proven track record at 3.5 bar(g) pressure differential and was traditionally the preferred solution for large polyolefin pneumatic conveying systems.然而，受国际制裁与出口管制影响，德国进口ZVH系列旋转阀的采购渠道受阻，原定进口供货方案被迫中止。面对项目工期压力与设备缺口，Daelim与业主紧急启动替代供应商评估程序。上海科全工程技术有限公司提交的GVH系列高压旋转阀在技术规格审查、样机测试及性能对比中表现优异，关键指标达到甚至部分优于德国同等系列产品，随后获得批准并实现替代供货。However, international sanctions and export controls blocked procurement channels for the German-imported ZVH series, forcing the original import plan to be suspended. Facing schedule pressure and an equipment shortfall, Daelim and the owner urgently launched an alternative supplier evaluation. Shanghai Conque’s GVH series performed excellently in technical specification reviews, prototype testing, and performance benchmarking, meeting or even exceeding key metrics of the German equivalent, and was ultimately approved as the replacement.2.3 40万吨PE装置密相输送的工况特点2.3 Operating Conditions of the 400,000 t/y PE Dense-Phase Conveying System年产40万吨PE装置属于大型合成树脂生产装置，其气力输送系统需满足以下严苛工况：A 400,000 t/y PE plant is a large-scale synthetic resin production facility whose pneumatic conveying system must meet the following demanding conditions:· 高压差工况：密相输送系统运行压力差通常在1.5~3.5 bar（g）甚至更高，要求旋转阀具备足够的结构强度与密封能力；High pressure differential: The dense-phase system operates at pressure differentials typically from 1.5 to 3.5 bar(g) or higher, requiring the rotary valve to have adequate structural strength and sealing capability.· 低气速高浓度：密相输送物料线速度低（一般低于5 m/s），固气比高（>25），可有效减少PE颗粒破碎与粉化，保证成品质量；Low velocity, high concentration: Dense-phase conveying keeps material line velocity low (generally below 5 m/s) with high solid-to-gas ratios (>25), effectively reducing PE pellet breakage and fines generation to ensure product quality.· 连续稳定供料：旋转阀作为系统的定量供料与锁气密封核心，必须在高压差下保持稳定的容积输送效率，避免脉动与断料；Continuous, stable feeding: The rotary valve serves as the core metering and air-locking element, and must maintain stable volumetric efficiency under high pressure differential without pulsation or material starvation.· 耐磨损与耐腐蚀：PE颗粒虽非强磨蚀性物料，但长期运行中仍要求阀体、转子及密封件具备优良的耐磨与耐老化性能；Wear and corrosion resistance: Although PE pellets are not highly abrasive, long-term operation still requires excellent wear and aging resistance in the valve body, rotor, and seals.· 低温适应性：俄罗斯地处高纬度，装置部分区域环境温度低，对设备材料低温韧性及轴承润滑提出额外要求。Low-temperature adaptability: Russia’s high-latitude location means low ambient temperatures in some plant areas, imposing additional requirements on material toughness at low temperatures and bearing lubrication.三、GVH系列高压旋转阀技术方案3. GVH Series High-Pressure Rotary Valve Technical Solution3.1 密相气力输送中旋转阀的核心作用3.1 Core Role of the Rotary Valve in Dense-Phase Conveying在密相气力输送系统中，高压旋转阀（High Pressure Rotary Valve）承担两项核心功能：一是定量供料，将料仓中的PE颗粒按工艺要求的流量均匀、连续地送入输送管道；二是锁气密封，在阀体上下游维持设定压力差，有效减少高压压缩空气向上泄漏，从而保证 motive air 有效用于物料输送而非损耗。In a dense-phase pneumatic conveying system, the high-pressure rotary valve performs two core functions: (1) quantitative feeding—uniformly and continuously delivering PE pellets from the silo into the conveying line at the process-required flow rate; and (2) air-locking—maintaining the set pressure differential across the valve to minimize leakage of high-pressure compressed air upward, ensuring that motive air is effectively used for material transport rather than lost.与稀相输送相比，密相输送采用更高的工作压力（通常>1.03 bar(g)）和更低的气量，物料在管道中以集团流（plug flow）或沙丘流（dune flow）状态推进，颗粒速度低、料气比高，对PE这类易破碎的颗粒料尤为适合。Compared with dilute-phase conveying, dense-phase conveying employs higher operating pressure (typically >1.03 bar(g)) and lower air volume. The material advances through the pipeline in plug flow or dune flow regimes with low particle velocity and high solid-loading ratio, making it particularly suitable for friable pellet materials such as PE.3.2 GVH系列高压旋转阀——替代进口的技术底气3.2 GVH Series—The Technical Confidence to Replace ImportsGVH系列是上海科全工程技术有限公司针对高压差、大产能密相输送工况自主研发生产的高压旋转阀产品。该系列对标德国德国进口ZVH系列同等规格，在结构设计、材料选型、密封系统及性能指标上经过严格对标与优化，成功通过Daelim及业主的严苛审查，成为该项目的正式供货方案。其关键技术特点如下：The GVH series is a high-pressure rotary valve independently developed and manufactured by Shanghai Conque for high-pressure-differential, large-capacity dense-phase conveying duties. Benchmarked against the German-imported ZVH series equivalent, it underwent rigorous design, material selection, sealing system optimization, and performance alignment, successfully passing Daelim’s and the owner’s stringent reviews to become the final supply solution. Key technical features are as follows:技术参数 / Technical Parameter说明 / Description设计压力 Design pressure3.5 bar(g)（约0.35 MPa），满足密相输送高压差需求，与德国进口旋转阀ZVH系列同级 3.5 bar(g) (approx. 0.35 MPa), meeting the high-pressure-differential demand of dense-phase conveying, on par with the German-imported ZVH series.转子结构 Rotor structure高压H型转子，闭式转子配轴向浮动密封，12腔室设计，填充率高，容积效率稳定 High-pressure H-rotor, closed rotor with axial floating seals, 12-pocket design, high filling rate, stable volumetric efficiency.进料口结构 Inlet geometry防卡料鹰嘴结构（chop-avoiding inlet），有效防止PE颗粒在入口卡滞，对标进口设计 Chop-avoiding inlet design effectively preventing PE pellet jamming at the inlet, benchmarked against imported designs.密封系统 Sealing system浮动径向密封 + 双唇轴封，单点可调，泄漏量极低，高压差下密封性能媲美进口产品 Floating radial seal + double-lip shaft seal, single-point adjustable, extremely low leakage, sealing performance comparable to imported products under high pressure differential.轴承配置 Bearing arrangement防尘深沟球轴承，终身润滑，密封转子轴承，适应长期连续运行，维护量小 Dust-proof deep-groove ball bearings, lifetime lubrication, sealed rotor bearings, suitable for long-term continuous operation with low maintenance.材料 Materials阀体与转子采用不锈钢或碳钢，可选耐磨涂层，适应化工工况及俄罗斯低温环境 Valve body and rotor in stainless or carbon steel, optional wear-resistant coating, adapted to chemical processes and Russia’s low-temperature environment.使用温度 Operating temperature-25℃ ~ +250℃，满足俄罗斯低温环境及工艺高温工况，低温韧性通过验证 −25 °C to +250 °C, meeting Russia’s low-temperature environment and high-temperature process conditions, with verified low-temperature toughness.排气系统 Venting system一体式排气口 + 腔体呼吸口，平衡转子腔室内压力，降低启动冲击，运行平稳 Integrated vent port + housing breather, balancing pressure inside the rotor chambers, reducing start-up shock and ensuring smooth operation.3.3 与进口产品的性能对标3.3 Performance Benchmarking Against the Imported Product在替代德国进口旋转阀方案评审阶段，上海科全提供了GVH系列与德国进口ZVH系列的全面对比数据：在同等工况（3.5 bar(g)压力差、PE颗粒、40万吨/年产能）下，GVH系列的容积效率、空气泄漏率、轴承温升、运行噪音等核心指标均达到ZVH系列同等水平。其中，GVH系列在转子密封结构上进行优化，采用单点可调式浮动径向密封，现场维护更为便捷；进料口防卡料结构经改进后，对PE颗粒的适应性进一步提升。During the import-substitution review, Shanghai Conque provided a comprehensive comparison between the GVH series and the German-imported ZVH series. Under identical conditions (3.5 bar(g) pressure differential, PE pellets, 400,000 t/y capacity), the GVH series achieved parity with the ZVH series in core metrics including volumetric efficiency, air leakage rate, bearing temperature rise, and operating noise. The GVH series further optimized the rotor sealing structure with a single-point adjustable floating radial seal for easier on-site maintenance, and improved the chop-avoiding inlet geometry to enhance adaptability to PE pellets.Daelim工程团队在收到上海科全提交的详细计算书、性能曲线图、材料质保文件及样机测试报告后，经多轮技术澄清与现场考察，正式确认GVH系列满足项目全部技术规格要求，批准其作为ZVH系列的替代方案。After receiving Shanghai Conque’s detailed calculation reports, performance curves, material quality assurance documents, and prototype test reports, Daelim’s engineering team conducted multiple rounds of technical clarification and site visits, ultimately confirming that the GVH series fully met the project’s technical specifications and approving it as the replacement for the ZVH series.3.4 空气管理单元（AMU）与系统协同3.4 Air Management Unit (AMU) and System IntegrationGVH系列高压旋转阀与配套空气管理单元（Air Management Unit）协同工作，在设定气流量下实现PE颗粒的密相正压输送。空气管理单元对进入输送管道的补充气进行精确分配，确保物料以低速度、高浓度状态平稳推进，避免管道堵塞与物料破碎。The GVH series high-pressure rotary valve works in conjunction with a dedicated Air Management Unit (AMU), achieving dense-phase positive-pressure conveying of PE pellets at a set airflow. The AMU precisely distributes supplemental air into the conveying line, ensuring that material is transported smoothly at low velocity and high concentration, preventing pipeline blockage and material degradation.该系统配置使得输送管道弯头磨损显著降低，管道使用寿命延长；同时，PE颗粒的破碎率与粉化率大幅下降，成品质量稳定，符合高端聚烯烃产品对粉尘含量的严格要求。This system configuration significantly reduces elbow wear in the conveying pipeline and extends pipeline service life. At the same time, the breakage and dusting rates of PE pellets are greatly reduced, product quality remains stable, and the finished product meets the strict dust-content requirements of high-grade polyolefins.四、项目执行与交付4. Project Execution and Delivery4.1 设计审查与国产化替代审批4.1 Design Review and Localization Substitution Approval项目由韩国大林工程公司（Daelim Engineering）负责详细设计与关键设备采购。在进口方案受阻后，Daelim启动了严格的替代供应商技术评估程序。上海科全在评估阶段提供了完整的GVH系列技术资料，包括：Daelim Engineering was responsible for detailed engineering and key equipment procurement. After the import plan was blocked, Daelim initiated a rigorous alternative-supplier technical evaluation. Shanghai Conque submitted a complete GVH series technical package, including:· 设备选型计算书及压力损失模型，证明GVH系列在40万吨PE装置工况下的适配性；Equipment selection calculations and pressure-loss models proving the GVH series’ suitability for the 400,000 t/y PE plant duty;· 与德国进口ZVH系列的逐项性能对比表，涵盖泄漏率、容积效率、耐压等级、材料规格等关键指标；Item-by-item performance comparison tables against the German-imported ZVH series covering leakage rate, volumetric efficiency, pressure rating, and material specifications;· 第三方检测机构出具的样机性能测试报告；Prototype performance test reports issued by third-party inspection agencies;· 质量管理体系认证（ISO9000）及原材料质保文件；ISO 9000 quality management system certification and raw material quality assurance documents;· 既往国内大型聚烯烃项目（如40万吨PVC、40万吨LDPE等）的运行业绩证明。Operating performance records from previous large domestic polyolefin projects (e.g., 400,000 t/y PVC, 400,000 t/y LDPE, etc.).经Daelim工艺团队、业主代表及第三方检验机构联合审查，GVH系列高压旋转阀随后获得批准，正式替代原定进口的ZVH系列，成为项目供货方案。Following joint review by Daelim’s process team, the owner’s representatives, and a third-party inspection agency, the GVH series high-pressure rotary valve was formally approved, officially replacing the originally planned imported ZVH series and becoming the project supply solution.4.2 制造与质量控制4.2 Manufacturing and Quality ControlGVH系列高压旋转阀的制造严格遵循上海科全企业内部技术规范与质量管理体系。关键零部件如转子、阀体、密封件均经过精密加工与严格检测。出厂前完成压力测试、气密性测试、运转试验及噪音检测，确保每台设备在3.5 bar(g)工作压力下保持极低的空气泄漏率与稳定的容积效率。Manufacturing of the GVH series strictly followed Shanghai Conque’s internal technical specifications and quality management system. Key components such as rotors, valve bodies, and seals were precision-machined and rigorously inspected. Before shipment, each unit underwent pressure testing, airtightness testing, running tests, and noise measurement to ensure extremely low air leakage and stable volumetric efficiency at 3.5 bar(g) operating pressure.4.3 终交与验收4.3 Final Acceptance项目于2025年顺利完成终交（Final Acceptance）。在装置试运行阶段，GVH系列高压旋转阀经受了连续运行考核，系统输送能力、物料计量精度、密封性能及噪音指标均满足合同约定的性能保证（Performance Guarantee）要求。业主组织现场验收，对设备运行稳定性及上海科全的技术支持给予高度评价。The project achieved final acceptance in 2025. During plant commissioning, the GVH series high-pressure rotary valves passed continuous operation trials, with system conveying capacity, material metering accuracy, sealing performance, and noise levels all meeting the contractual performance guarantee requirements. The owner organized on-site acceptance and gave high praise for equipment stability and Shanghai Conque’s technical support.【】 （附：业主现场验收照片，展示GVH系列高压旋转阀安装就位及运行调试场景） (Attached: on-site acceptance photos showing GVH series high-pressure rotary valve installation and commissioning.)五、应用效果与业主评价5. Application Results and Owner Evaluation该项目投运后，GVH系列高压旋转阀在40万吨PE装置密相输送系统中表现出以下突出优势：After commissioning, the GVH series high-pressure rotary valves demonstrated the following outstanding advantages in the 400,000 t/y PE plant dense-phase conveying system:· 计量精度高：旋转阀容积效率稳定，PE颗粒供料均匀，保证了下游挤压造粒工段进料稳定；High metering accuracy: Stable volumetric efficiency and uniform PE pellet feeding ensured stable downstream feed to the extrusion pelletizing section.· 密封性能优异：在3.5 bar(g)高压差下，空气泄漏量极低，压缩机功耗得到有效控制，系统能耗降低；Excellent sealing performance: Extremely low air leakage at 3.5 bar(g) pressure differential effectively controlled compressor power consumption and reduced system energy use.· 物料破碎率低：密相输送低气速特性使得PE颗粒在输送过程中几乎无破碎，成品粉尘含量显著低于稀相输送方案；Low material breakage rate: The low-velocity characteristic of dense-phase conveying meant almost no pellet breakage during transport, with finished-product dust content significantly lower than dilute-phase alternatives.· 运行可靠性高：连续运行考核期间，旋转阀无卡料、无异常振动，轴承温升正常，维护量小；High operational reliability: During continuous operation trials, the rotary valves showed no jamming, no abnormal vibration, normal bearing temperature rise, and low maintenance requirements.· 低温适应性好：设备在俄罗斯冬季低温环境下启动与运行正常，润滑系统及密封材料无异常。Good low-temperature adaptability: Equipment started and operated normally in Russia’s winter low-temperature conditions, with lubrication and sealing materials showing no anomalies.业主（俄罗斯石油公司）在验收报告中指出：由上海科全供应的GVH系列高压旋转阀及配套技术服务，在性能上完全替代了原定进口的德国同等系列产品，设备运行稳定可靠，技术文件完整，售后服务响应及时，同意通过验收。In the acceptance report, the owner (Russian oil company) stated that the GVH series high-pressure rotary valves and accompanying technical services supplied by Shanghai Conque completely replaced the originally planned German equivalent in performance; the equipment operated stably and reliably, technical documentation was complete, and after-sales service was responsive, and therefore final acceptance was approved.六、结语6. ConclusionGVH系列高压旋转阀在40万吨PE大型装置中的成功应用，不仅验证了国产高压旋转阀在密相气力输送领域的技术实力，更体现了在国际制裁背景下中国高端装备实现进口替代的可行路径。The successful application of the GVH series high-pressure rotary valves in a 400,000 t/y large-scale PE plant not only validates the technical strength of domestic high-pressure rotary valves in dense-phase pneumatic conveying, but also demonstrates the feasible path for Chinese high-end equipment to achieve import substitution amid international sanctions.随着全球聚烯烃产能持续扩张及国际供应链格局变化，大型PE/PP装置对高效、低破损、低能耗的物料输送需求日益增长。上海科全将继续深化GVH系列高压旋转阀的技术迭代，结合自主开发的PneuCalc气力输送计算工具与散料装车计算平台，为国内外石化客户提供从工艺计算、设备选型到安装调试的全流程技术服务，助力中国高端气力输送设备与系统解决方案走向世界。As global polyolefin capacity continues to expand and international supply chains evolve, large-scale PE/PP plants increasingly demand efficient, low-breakage, low-energy material conveying. Shanghai Conque will continue to deepen the technical iteration of the GVH series high-pressure rotary valves, integrating its self-developed PneuCalc pneumatic conveying calculation tool and bulk loading calculation platform to provide domestic and international petrochemical customers with full-process technical services from process calculation and equipment selection to installation and commissioning, helping Chinese high-end pneumatic conveying equipment and system solutions reach the global stage. —— 上海科全工程技术有限公司 / Shanghai Conque Engineering Technology Co., Ltd. —— www.shconque.com
