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Successful energy-saving implementation of ultrasonic scale prevention in Baihong Petrochemical’s PTA refining preheater

2025-08-21View Original

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According to a report by Quanzhou Economic Network on October 11, 2024: Traditionally regarded as major consumers of energy, petrochemical enterprises have always been synonymous with high electricity consumption and high energy usage. However, at Baihong Petrochemical, this “stereotype” was reversed. “The power consumption of a company’s PTA (pure terephthalic acid) production facilities is around 40,000 kWh per hour; under traditional power supply methods, this would result in substantial costs for the company. ”Mao Yiliang, deputy general manager of Baihong Petrochemical, explained that the company employs advanced energy recovery technologies to fully recover the heat energy generated during production and convert it into electrical power; this allows for a power generation capacity of up to about 60,000 kWh per hour. “Thanks to this advanced technology, the electricity we generate each year not only meets our own energy needs but also allows us to supply any excess power back to the grid, enabling us to operate as a truly ‘green factory’ and significantly reducing the company’s operating costs.” Baihong Petrochemical’s \"green magic weapons\" don’t stop there. Adhering to the philosophy of \"identifying, solving, and improving problems at the front line,\" the company leverages the wisdom and innovation of its frontline employees and technical staff to introduce numerous innovative technical improvement projects and achievements. For example, in the case of the ultrasonic descaling project for refined preheaters, 62,500 tons of high-pressure steam are saved each year, resulting in an energy savings of 6,112 tons of standard coal ; The renovation of the low-pressure circulating water pump results in annual energy savings of 8.4 million kWh, as well as a reduction in energy consumption equivalent to 1,032 tons of standard coal, and so on. In addition, the projects for hydrogen bromide recovery from the carbon-neutralization washing water generated by PTA oxidation waste gas, as well as those for carbon emission reduction through technological upgrades, are expected to come online by the end of October this year. Construction of this project officially began in February 2023, with the aim of capturing carbon dioxide generated during the manufacturing process and reusing it in production to turn it into valuable \"products\". Mao Yiliang explained, \"Regarding the exhaust gases generated as a result of the oxidation reactions in the devices, we use new carbon-reduction technologies and add specific chemical substances for washing and absorption. This allows us to capture the carbon dioxide produced by catalytic combustion and convert it into useful products that can be recycled, thereby achieving the goal of reducing carbon emissions.\" ”Once operational, this project is expected to capture and utilize 2,119 to 2,319 tons of carbon dioxide per year, reduce wastewater discharge and save 336,000 tons of industrial water consumption, while generating annual revenues of over 20 million yuan for the enterprise. Special note: The ultrasonic descaling project for precision preheaters carried out by this company does not utilize ordinary ultrasonic technology; instead, it makes use of our company’s special ultrasonic technology – long-pulse ultrasonic technology. For technical exchanges, use WeChat: TigerPeng2014. Compared with the first-generation short-pulse ultrasonic scale prevention and removal technology, the long-pulse ultrasonic scale prevention and removal technology represents a different technological generation, and the main differences between the two are as follows: (1) Different effective working times. The pulse width of short-pulse devices is very short, only a few milliseconds, usually 2.5 ms (with a maximum of 5 ms), and the pulse interval is fixed at 80 ms; thus, the effective working time per second is only around 30.3 ms. The pulse width of the long-pulse device can be adjusted between 100ms and 500ms, and the pulse interval can also be adjusted within the same range. The maximum effective operating time per second is 833.33ms, which is approximately 27.5 times that of short pulses. (II) Different equipment powers: The short-pulse device consists of 1 main unit equipped with 4 transducers; the average power of each transducer is around 30 W, which is relatively low, resulting in weak capabilities for preventing and removing scale. Long-pulse devices consist of one main unit paired with one transducer; the average power of each transducer is around 200W–400W, which is 8–10 times higher than that of short-pulse devices, granting them stronger capabilities for preventing and removing scale.

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