Weihua Group comprehensively \"unlocks skills\" and raises standards to \"improve quality and efficiency\"”

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Weihua Group unlocks skills in all aspects and strives for higher quality and efficiency. Author/Source: Weihua Group Date: 2021-11-23 Clicks: 24 As the end of the year approaches, in the synthesis workshop of Weihua Company, employees are working hard to unlock their skills in every way, working together to meet higher standards and achieve the annual production targets. “Deploying resources to carry out technical upgrades, as well as strengthening comparisons with leading companies in the same industry to ensure achievement of the company’s annual targets, is one of the items on the company’s overall task list for cost reduction and efficiency improvement in 2021. In the corresponding entry for this column, the synthesis workshop, as a front-line production facility, takes \"ensuring the stable operation of the equipment and striving to increase its operational rate and load factor\" as its specific goal. When facing a series of insurmountable problems such as equipment aging, breaking through production bottlenecks becomes particularly important. By conducting a comprehensive analysis of the process flow, the workshop addressed the issue that the synthesis section, affected by the temperature of the circulating water, was unable to provide sufficient cooling for the system. By adding an additional water cooler, E1901—3, the purpose of increasing the heat exchange area at the outlet of the ammonia compressor was achieved, thereby ensuring more stable full-load operation of the ammonia synthesis process. This technological upgrade is, for the facility, akin to a strategic reorganization of resources; it represents another significant step forward in reducing costs and increasing efficiency, thereby opening up new possibilities for higher production levels from the facility. “Reduce waste and save real money. Strengthen the inspection and management of sewage drainage in various areas, actively organize the implementation of water-saving renovation projects to reduce water consumption per unit of product, and at the same time improve the control of leaks in water systems to prevent waste of water resources. ”The equipment modifications carried out this month in the workshop’s spare parts department for the P60 and P61 water pumps represent, without a doubt, the best implementation of the task related to \"reducing costs and increasing efficiency\" on that list. “We have replaced the previous packing seals with mechanical seals. Don’t underestimate this small change – it allows for a water savings of at least 50 kilograms per hour. In addition, while in the past the packing needed to be replaced 2-3 times per month, with mechanical seals the frequency of maintenance is now virtually zero. Over time, the cost savings resulting from reduced maintenance efforts are also significant. ”Regarding this renovation of the water pump equipment, Tsang Kun, a process technician specializing in air separation technology, did some calculations for us. Whether from the perspective of water conservation or maintenance, even a drop of water can eventually accumulate into a stream, helping the company save real money by improving its efficiency. “Through comprehensive planning, responsibility targets are refined. The four sections under the synthesis workshop have their technical personnel, under the unified guidance of the company’s Production Department’s ‘Implementation Rules for Improving Quality and Efficiency’, determine the overall direction based on the conditions of that year. They then refine these into specific targets for each section, taking into account the unique characteristics of each section’s operations, while ensuring that responsibilities are assigned to individual persons. We can say that this matter has been ongoing since the beginning of the year until now, at the end of the year. ”When talking about the workshop’s summary of work for this year’s \"Year of Efficiency Improvement,\" Workshop Director Li Jinheng began by saying, \"For example, the use of liquid nitrogen to treat exhaust gases before feeding them into the boiler for combustion – although this is just a small-scale technical improvement project – it enables the reuse of hot steam, thereby saving fuel used in boiler combustion. This is an example of practical measures taken to save energy and reduce consumption,\" Li Jinheng continued, giving more examples. In addition, it is necessary to reasonably reduce the consumption of various chemical raw materials ； Improve various process parameters to reduce operational fluctuations and abnormal venting caused by improper operating parameters ； Strengthen the management of repairing and reusing existing assets; for components that are replaced, it is necessary to thoroughly assess the economic viability of repairing them in order to make the best use of such assets ； Measures such as reducing the consumption of spare parts and preventing wear and tear due to excessive maintenance are all detailed systems formulated from various perspectives, aimed at comprehensively improving the operational quality of the equipment and achieving higher standards. Recently, workshop managers and technical staff conducted another comprehensive analysis of the operation rates and load factors of air separation and ammonia synthesis processes from the previous month, and carried out horizontal and vertical comparisons of the production volumes of the by-products oxygen, nitrogen, argon, and sulfur. A thorough inspection and summary are conducted of the implementation status of the measures aimed at reducing costs and increasing efficiency. Based on factors such as changes in various process parameters and current market conditions, timely controls and adjustments are made to the measures to be adopted this month, with the goal of achieving even higher standards as part of the effort to make this a year of improved efficiency.