【Learning from Others’ Successes】Jilin Petrochemical’s ABS Plant Generates Millions in Profits from a Small Scale Operation

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In 2026, during the 25th National “Safety Production Month”, everyone is encouraged to prioritize safety and be capable of responding to emergencies; efforts are also being made to identify and rectify potential risks and hazards. -------------------------------------------------- Taking the optimization of its utility systems as a starting point, Jilin Petrochemical’s ABS plant meticulously calculates the value of even the smallest resources—such as a single drop of water, one unit of electricity, or one cubic meter of gas. As a result, it has managed to generate millions of yuan in benefits from these seemingly insignificant resources. Just how valuable can a single drop of water, one unit of electricity, or one cubic meter of gas really be? The ABS plant of Jilin Petrochemical Company reported that in the first five months of this year, optimization of the utility systems alone generated savings of 13.14 million yuan. Since the beginning of this year, the ABS plant of Jilin Petrochemical Company has taken the optimization of its utility systems as a starting point, integrating the \"Mada Mao spirit\" into production management. By encouraging all employees to pay close attention to details and conduct thorough cost analyses, the company has managed to achieve tangible economic benefits through meticulous control at every level. The cost-benefit analysis of a single drop of water: \"Can using filtered water instead of desalinated water really not affect quality?\" ”In the face of doubts, the technical staff from the company’s production and operation department provided answers through action. They went to the site of the online high-pressure cleaning system in the graft polymerization reactor, conducted repeated evaluations, and installed filters along the existing water pipelines, using the water that had been purified a second time for cleaning the polymerization reactor. After rigorous testing, its product quality is indistinguishable from that of products using expensive deionized water. The second and fourth ABS units were subsequently modified. They also optimized the condensed acidic water recycling system of the fourth ABS unit, reducing the consumption of filtered water by an average of 22 tons per hour. This has led to a daily reduction of over 500 tons in wastewater discharge. At the fourth ABS facility, the plant staff did some calculations: 24 latex pumps consume 61,000 tons of seal water throughout the year; by implementing the recycling of this seal water, it is possible to reduce the consumption of demineralized water and the amount of wastewater generated by the same amount each year. To reduce costs per unit of electricity, in the ice machine room of the fourth ABS unit’s PBL section, technicians adjusted the feeding times for the 8 reaction vessels. Leveraging the advantage of pipeline interconnection, the chiller operation mode is changed from \"two units in parallel\" to \"one in use and one as backup\", saving thousands of kilowatt-hours of electricity per hour. At the same time, the production and operation department took the lead in coordinating the workshop technicians to work on improving the circulating water system; through precise control of individual devices, the consumption of circulating water was reduced by 9,000 cubic meters per hour ； Two 5,000 cubic meters per hour large pumps and one hot oil circulation pump were shut down, saving 62,000 kWh of electricity per day. In the first five months of this year, the two measures collectively generated over 5 million yuan in benefits. The company also has clever ways to save electricity when pumps operate intermittently: it optimizes the operating times of wastewater pumps, feed fans, mixers, etc., avoiding peak hours while still meeting the process requirements. According to calculations, this alone can save 4.9 million yuan in electricity costs per year. Energy-saving tips: The nitrogen system is a major consumer of energy, yet it also represents a rich source for improving energy efficiency. The company’s production and operation department, in collaboration with various workshops, carefully examined each aspect related to nitrogen sealing of storage tanks, powder drying, and the conveying systems. Through on-site pressure adjustment, leak repair, and optimization efforts, it was possible to reduce the hourly nitrogen consumption by 350 cubic meters. In early March, prior to the hot oil heater for the fourth ABS unit, process engineers repeatedly optimized the load curve; as a result, the hourly natural gas consumption decreased by 420 cubic meters compared to the beginning of the month. The operator said, “Adjusting the furnace now requires more precision than adjusting a gas stove.” ” Heating tracing systems are also very cost-conscious. Technicians keep a close eye on temperature changes, carrying thermometers as they inspect every factory building. By increasing the frequency of on-site temperature measurements, they provide special monitoring for critical areas such as pipes prone to freezing and remote sensors; merely for steam and hot water, this approach results in cost savings of 135,000 yuan per day. In the first five months of this year, the company’s ABS unit achieved savings of 5.21 million yuan by making optimal use of steam, truly making the most of every unit of gas and heat available. Friendship links