Jiujiang Petrochemical, Zhenhai Refining & Chemical | Take a look at the highlights of the first batch of green model factories in 2017!

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　　To thoroughly implement the green manufacturing initiative, accelerate the establishment of a green manufacturing system, and establish a number of advanced models in this field, on September 1, the Ministry of Industry and Information Technology issued a notice titled \"Notice on Announcing the First Batch of Green Manufacturing Demonstration Entities for 2017\", identifying 201 green factories, 193 green-designed products, 24 green industrial parks, and 15 enterprises that serve as models in terms of green supply chain management. Among them, Zhenhai Refining & Chemical and Jiujiang Petrochemical were selected as **the first batch of green manufacturing demonstration factories. 　　Green factories are the **core supporting units of the green manufacturing system, focusing on the greening of production processes. Since 2017, the Ministry of Industry and Information Technology has been carrying out evaluations for green manufacturing demonstration factories across the country. The evaluation of green factories includes 7 aspects: basic requirements, infrastructure, management system, investment in energy and resources, products, environmental emissions, and performance. The evaluation agency conducted a comprehensive and systematic assessment of Zhenhai Refining & Chemical and Jiujiang Petrochemical’s efforts in establishing green factories as well as their performance levels, based on 7 dimensions, and confirmed that they meet the requirements for green factories. 　　▲"On the backend of the process industry’s official WeChat account, by responding with “Green Factory”, one can view this list of the first batch of green manufacturing demonstration sites from 2017. 　　Jiujiang Petrochemical
In recent years, Jiujiang Petrochemical has made great efforts to foster two core competitive advantages: “green and low-carbon” operations and “smart factories”. In 2016, Jiujiang Petrochemical processed 7.25 million tons of crude oil throughout the year, generating sales revenue of 32.6 billion yuan and an accounting profit of nearly 2 billion yuan ； 12.3 billion yuan in taxes and fees were paid, ranking first in Jiangxi. 　　In July 2015, Jiujiang Petrochemical was successfully selected as a **Ministry of Industry and Information Technology pilot enterprise for intelligent manufacturing. In May of this year, the processing volume of crude oil exceeded 700,000 tons for the first time; the key technical and economic indicators improved significantly and all met the required standards. High-value-added products such as gasoline, aviation fuel, liquefied gas, and carbon-5 blowing agents all reached record levels. Profit per ton of oil and total profit have once again ranked first among the refineries and chemical plants along the river, reaching the best levels since the commissioning of the 8 million tons/year facility. 　　In pursuing green and low-carbon development, Jiujiang Petrochemical not only implements strict control at the source but also applies hierarchical regulation to the emission levels of pollutants during the production process, strictly curbing abnormal emissions. Additionally, it conducts environmental factor identification and risk assessment on a monthly basis to identify potential environmental hazards. On the basis of the stable operation and compliance with emission standards of the 5 sets of oil and gas recovery and odor control facilities that are already in use, measures such as improving the sealing of wastewater, waste liquid and waste residue systems, as well as optimizing tank designs and loading/unloading methods, are employed to effectively control emissions from process gases, volatilization losses during storage in tanks and during loading/unloading operations, leaks from wastewater, waste liquid and waste residue systems, as well as pollution emissions under abnormal operating conditions. 　　Supported by smart factories, the management and business processes at Jiujiang Petrochemical have been further optimized. By leveraging the achievements of smart factory construction, real-time databases for environmental information as well as relational databases have been established, enabling timely detection of changes in pollutants and related production data. This approach results in annual savings of nearly 10 million yuan in costs associated with hazardous waste treatment, delivering both environmental and economic benefits. 　　Model for the construction of intelligent petrochemical factories Jiujiang Petrochemical New Area The factory in this new area, which began operations in October 2015 at the new Jiujiang Petrochemical site, does not feature busy workers; it relies entirely on automated, intelligent production methods. It is China’s first model facility for the construction of intelligent factories. 　　Since 2012, enterprises have adopted advanced information technologies to integrate deeply with the most fundamental aspects of petrochemical production, thereby establishing intelligent petrochemical factories characterized by real-time sensing, digitalized equipment, high-speed networks, standardized data, and integrated applications. In July 2015, Jiujiang Petrochemical was successfully selected as a **Ministry of Industry and Information Technology pilot enterprise for intelligent manufacturing. 　　The main application systems of Jiujiang Petrochemical’s smart factory include: centralized integration and standardization of master data for production operations; wired and wireless broadband networks and communication convergence in industrial enterprises; a fully 3D digital refinery based on engineering design and business requirements (the first of its kind in China); and various mechanistic and business models. 　　These technologies are deeply integrated with next-generation information technologies such as new types of sensors, the Internet of Things, big data analysis for optimization, cloud platforms, and mobile computing. This integration enhances the real-time monitoring capabilities, mechanism analysis capabilities, model prediction capabilities, and scientific decision-making abilities of petrochemical process-based enterprises, thereby significantly improving their safety and environmental protection performance, economic efficiency, and management effectiveness. It also provides strong support for the improvement of the quality, efficiency, and competitiveness of Jiujiang Petrochemical’s operations. 　　With the support of smart factories, Jiujiang Petrochemical has further optimized its flat and matrix-based management structure as well as its business processes. Despite the continuous increase in production capacity and processing facilities, by 2016 the total number of employees at Jiujiang Petrochemical had decreased by 14% compared to the beginning of 2011, while the number of work teams dropped by 13%; management efficiency has continued to improve. 　　Wastewater treatment tanks suitable for raising fish: The wastewater treatment observation tank at Jiujiang Petrochemical contains a large number of koi fish. It can be seen from this observation tank that, after going through a series of treatment processes such as purification and filtration by microorganisms in biological treatment tanks, adsorption by activated carbon, and high-pressure degradation, the water discharged is clear and odorless. Dozens of ornamental fish are also kept in this tank to monitor changes in water quality. In 2016, the average oil content, COD, and ammonia nitrogen levels in the total wastewater inflowing to the factory’s wastewater treatment plant decreased by 68%, 26%, and 38% respectively compared to the previous year. 　　Leveraging the achievements of building \"smart factories,\" these enterprises were among the first in the petrochemical industry to develop and implement \"environmental protection maps\" that enable real-time online monitoring of pollutant emissions from various facilities, enhancing early warning capabilities. This approach facilitates visual and integrated environmental management, allowing for full-process monitoring of the generation, treatment, and discharge of pollutants. The fish kept in the tanks also serve as an indicator to detect changes in water quality. When a problem occurs, abnormal data will be sent immediately to the responsible persons at Jiujiang Petrochemical and relevant staff via their mobile phones, and the cause will be identified and the issue resolved within one hour. 　　An electronic screen displaying real-time water quality data is installed beside the wastewater treatment observation tank; the readings show that COD is 30.460 mg/l ； Oil 2.960mg/l ； NH3-N: 0.360 mg/l (**Emission standards: COD ≤ 60 mg/L, Oil ≤ 5 mg/L, Ammonia nitrogen ≤ 8 mg/L); the wastewater treatment quality parameters of Jiujiang Petrochemical are far superior to these **standards. 　　Jiujiang Petrochemical has established a comprehensive online real-time environmental monitoring system; data from 5 nationally monitored sites, including the main sewage discharge outlet, is uploaded in real time to the provincial and municipal environmental protection online platforms. The system’s operational efficiency is above 99%, and the rate of successful data transmission is over 98.8%, which exceeds the **established standards. In 2016, the Jiujiang Petrochemical Environmental Monitoring Station successfully passed **laboratory accreditation. 　　Zhenhai Refining & Chemical: Egrets, fish ponds, green grass… These are the scenes one can see in the refinery, and they have become a normal part of life at Sinopec Zhenhai Refining & Chemical. Previously, \"unsafe,\" \"unenvironmental,\" and \"closed\" were the images of petrochemical companies in people’s minds. 　　Green petrochemicals: philosophy first. A gentle breeze blows, with egrets flying softly in the air. Approaching the LPG bottling station at Zhenhai Refining & Chemical, dozens of egrets were busy building nests back and forth. Upon closer inspection, the grove where the egrets build their nests is flanked by a warehouse on one side and a liquefied gas station on the other. It is only a little over 100 meters away from the jet fuel storage tanks, and less than 500 meters from the nearest refining facility. 　　The endangered species, the egret, is known as nature’s \"ecological inspector\"; it is extremely picky about its living environment, settling only in places where the conditions are good and safe. Generally, flocks of egrets can be seen in the fields during the spring plowing season, but in Zhenhai Refining & Chemical, a group of egrets lives here contentedly, coming and going with the seasons. Egrets settle here because there are people who love and protect them, as well as a favorable ecological environment and a complete food chain. 　　Zhenhai Refining & Chemical is a flagship company under Sinopec, and it is currently the largest integrated refining and chemical enterprise in China. The company has a refining capacity of 23 million tons per year and an ethylene production capacity of 1 million tons per year. Its large scale and high efficiency, along with its leadership in environmental protection, are all made possible by Zhenhai Refining & Chemical’s green development philosophy of \"low costs, high efficiency, low emissions, and sustainability\". 　　What kind of philosophy there is determines what kind of actions will be taken. Zhenhai Refining & Chemical focuses on starting from the source, adopting advanced design concepts, clean production processes, and comprehensive utilization technologies to organize its production activities. 　　In 2012, in line with Sinopec’s unified plan for the \"Clear Waters and Blue Skies\" environmental protection initiative, the company invested over 920 million yuan over three years to carry out more than 20 environmental protection projects, including those for sulfur and nitrogen removal. 　　By the end of the 12th Five-Year Plan period, the company’s total emissions of sulfur dioxide and nitrogen oxides had been reduced by approximately 80% and 50%, respectively, compared to 2012. 　　In 2016, the company launched another round of environmental improvement projects, investing around 1 billion yuan to upgrade the treatment systems for sulfur exhaust gases and flue gases from heating furnaces. 　　It is expected that by 2018, the reduction rate of volatile organic compounds will reach 30%, further improving the overall level of environmental protection. Green production: making the most of everything. “It tastes great!” On March 23rd, during Zhenhai Refining & Chemical’s 111th public open day, some visitors were impressed after tasting water that had been treated by a wastewater recycling system and met drinking water standards. 　　In fact, as early as 2003, Zhenhai Refining & Chemical Co., Ltd. was the first to reuse untreated wastewater from its processes in the industrial cooling water system. Through more than a decade of operational experience, and by employing technologies such as \"integrated water-saving and emission-reduction systems,\" the company has managed to achieve near-zero discharge of industrial wastewater; moreover, the wastewater processed by specialized treatment devices can meet drinking water standards. 　　Let’s take a look at the data instead. From 2003 to the first quarter of 2016, the company reused a total of 72.63 million tons of wastewater, an amount equivalent to the storage capacity of five West Lakes in Hangzhou, with an industrial water reuse rate of 98.6%. 　　Zhenhai Refining & Chemical’s green philosophy runs through the entire production process. For example, the company utilizes exclusively hydrotreating processes for oil refining. Based on an annual crude oil processing volume of 22 million tons, this hydrotreating process can reduce the amount of wastewater generated by 550,000 tons per year. At the same time, advanced technologies and equipment are employed to implement life-cycle management of devices, enhancing their reliability and reducing pollutant emissions at the source. Throughout 2016, the company implemented 36 energy-saving projects, resulting in a energy savings of 57,800 tons of standard coal. 　　Not only does Zhenhai Refining and Chemicals make full use of its internal resources efficiently, but it also applies this approach of exploiting everything to the industrial chains outside the company. 　　“The main raw materials for our company’s products come from the C4 fraction obtained from the cracking processes at Zhenhai Refining & Chemical Co., which is used to produce petrochemical products with high added value; some of the by-products generated are then fed back to Zhenhai Refining & Chemical Co. ”Xu Qi, general manager of Ningbo Haode Chemical Industry Company located in the Ningbo Petrochemical Economic and Technological Development Zone, said. This company, which relies on Zhenhai Refining & Chemical for its livelihood, can generate annual output worth over a billion yuan. And these C4 compounds were previously mostly burned as fuel. 　　As a key enterprise in the Ningbo Petrochemical Economic and Technological Development Zone, Zhenhai Refining & Chemical has removed its walls and expanded beyond its factory boundaries, facilitating the mutual supply of products and by-products. Through this approach to circular economy, it has grown from a small scale to play a significant role within the chemical industrial park. The company supplies 167 types of materials to chemical enterprises within the park, and there are over 20 enterprises that exchange materials with each other; the total annual volume of such exchanged materials exceeds 2 million tons. The industrial chain benefits and environmental protection achievements achieved in this area rank among the best among similar chemical parks in China. Green products: turning waste into treasure. The concept of sustainability naturally leads to the creation of green products. Zhenhai Refining & Chemical is a pioneer in the upgrading of petroleum products in China. It was one of the first companies in the country to upgrade gasoline and diesel, as well as to supply 98-octane gasoline and low-sulfur diesel to the market. In 2014, the quality of gasoline produced by Zhenhai Refining & Chemical was upgraded to meet the National V standard. On January 1, 2017, Zhenhai Refining & Chemical Co., Ltd. fully implemented National V emission standards. Ensure that by the end of 2018, the production capacity for gasoline and diesel meets the National VI standards in full. 　　The problematic \"gutter oil\" that causes trouble for ordinary people can now be turned into something useful at Zhenhai Refining & Chemical Co., Ltd. as well. Relying on advanced technology, Zhenhai Refining & Chemical has managed to turn “gutter oil” into renewable, environmentally friendly biojet fuel. Huang Zhongwen, director of the Zhenhai Refining & Chemical News Center, said that China’s first large-scale biojet fuel production facility is set to begin construction by 2018. Once completed, it will be able to process 100,000 tons of used cooking oil per year, producing 30,000 tons of biojet fuel – an amount sufficient to meet the needs of regular flights to China’s most remote destinations on an annual basis. 　　Biojet fuel is made from food waste oils and non-edible animal and plant fats; it is a renewable, environmentally friendly fuel. 　　In September 2011, the Hangzhou petrochemical production facility of Zhenhai Refining & Chemical Corporation was upgraded to include a biological jet fuel production plant and blending facilities, becoming the first industrial-scale biological jet fuel production facility in Asia. 　　In December 2011, the facility produced qualified biojet fuel for the first time. 　　On March 21, 2015, Sinopec BioJet Fuel No. 1 successfully underwent a manned commercial flight. 　　In 2016, the feasibility study for the bio-jet fuel hydrogenation project was approved by Sinopec’s headquarters, and construction was set to begin at Zhenhai Refining & Chemical Complex in 2018. At present, all tasks are being carried out intensively. 　　At present, Zhenhai Refining & Chemical is actively working to optimize regional resources and expand its fine chemicals business, accelerating its progress into the field of high-end chemicals. 　　▲"On the backend of the process industry’s official WeChat account, by responding with “Green Factory”, one can view this list of the first batch of green manufacturing demonstration sites from 2017. 　　The content is sourced from various professional news outlets, including China Energy News, People’s Daily Online, and Haimai.com; we extend our thanks to them all. This article was edited and published by \"Process Industry\", and it is released here for the first time on this platform.