The Dushanzi Petrochemical and Tarim Petrochemical subsidiaries successfully completed the annual fertilizer production targets for 2021

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Dushanzi Petrochemical Tarim Petrochemical Branch successfully completed its annual fertilizer production targets for 2021. Author/Source: Dushanzi Online Official WeChat; Date: December 29, 2021; Views: 22. On December 13, the Dushanzi Petrochemical Tarim Petrochemical Branch successfully fulfilled its annual fertilizer production goals in 2021. It produced 828,800 tons of urea and sold 813,200 tons of urea (including 90,800 tons of functional urea). The branch generated revenues exceeding 1.4 billion yuan, achieving both the best-ever production performance and the best operating results in its history. This year, Tarim Petrochemical Branch has focused on the short-term, medium-term, and long-term goals for the long-term operation of its fertilizer plant. It has implemented 27 production control measures to ensure that the plant operates at full capacity. Strict controls are implemented for unplanned shutdowns of the plant. Five fundamental aspects of production—“shift handovers, inspections, screen monitoring, operating procedures, and labor discipline”—are rigorously strengthened. The operational stability rate exceeds 99.98%. The plant has operated continuously for 318 days while maintaining a positive trend. In particular, ammonia synthesis has achieved Class A continuous operation; for eight consecutive months, urea production has exceeded 80,000 tons, setting a new historical record. Images: Remarkable results have been achieved in technological research and development. By analyzing and addressing critical challenges related to decarbonization systems, circulating water systems, large-scale equipment, and instrumentation, 14 key projects have been steadily implemented, thereby ensuring the plant’s operation at high loads. Systematic efforts were made to develop decarbonization technologies, eliminating the bottlenecks that arise under high loads in the decarbonization system ； The operation of the circulating water was optimized to reduce the system backpressure and increase the flow rate in the terminal coolers, thereby improving the heat exchange efficiency ； Organized the K421 technological research and development efforts to identify the risks associated with adjusting power alarm thresholds, thereby resolving the issue of insufficient gas volume in K421 ； Under high-temperature conditions, the plant’s load increased by 10% year-on-year, while the normal operating load remained above 103%, marking a new milestone. We are a leader in the alarm management industry. To address the issue of excessive alarms in fertilizer plants, we have made great efforts to carry out specialized alarm management initiatives, following the approach of “improving systems, setting goals, leveraging technology, implementing measures in phases, starting with easier tasks before tackling more difficult ones, involving all parties in the process, making steady progress, conducting quantitative evaluations, and fostering good habits”. An alarm management mechanism has been established, along with preventive management measures. Early warnings for abnormal rate deviations have also been implemented. Additionally, a relational model diagram for process indicators was developed for the first time. This has led to the creation of a “Four Musts” working method: “Actions must be taken upon receiving an alarm; analysis must be conducted after handling an alarm; reports must be submitted after eliminating an alarm; and similar alarms must be investigated.” As a result, the daily number of alarms has dropped from a previous peak of 5,000 to less than 10. There have even been months where no alarms occurred for up to 18 days. These achievements place the company at the industry’s leading level. The efforts have been recognized and commended by the Group Company, the refining and petrochemical sector, and the leadership of Dushanzi Petrochemical Company, making it a benchmark model for alarm management within the industry. Benchmarking efforts have yielded fruitful results. By implementing the action plan for enhancing management to world-class standards at Dushanzi Petrochemical, benchmarking was carried out comprehensively by all employees across all processes and aspects. The design principles and concepts behind the fertilizer plant were thoroughly understood. From the perspectives of profitability, competitiveness, and sustainability, 26 benchmarking indicators were established, covering profit, production volume, energy consumption, manufacturing processes, safety, equipment, technology, and management innovation. These indicators were compared against the plant’s design values, historical best performance levels, and industry benchmarks. Throughout the year, 23 of these indicator targets were achieved, enabling Dushanzi Petrochemical to rank first among Category A units within the company ； Its main economic and technical indicators rank among the top in the industry. It has been recognized as an advanced unit in energy conservation and emission reduction during the 13th Five-Year Plan period by the China Nitrogen Industry Association, as well as a benchmark enterprise leading in water efficiency for ammonia synthesis by the China Petroleum and Chemical Industry Federation. Significant results have been achieved in equipment management. The concept of “integration of equipment and processes” has been established; the proportion of preventive and predictive maintenance has been increased; specialized inspections aimed at preventing leaks, fires, and explosions have been carried out diligently; and the practice of “tailoring measures to each piece of equipment” has been further implemented. Model cases of rectification for shortcomings in mechanical integrity have been identified. The overall equipment availability rate reached 99.99%, while the availability rate of critical equipment hit 100%, both reaching record highs. Carry out the “interlocked reinforcement” campaign. A dual-channel transmitter is employed, with the addition of double-point interlocks and a single-point interlock rate alarm. The interlock activation rate and the automatic control activation rate both reach 100%. Prepare a work outline for preventing power fluctuations; install leakage protection systems in maintenance boxes and electric trace heating boxes; conduct a comprehensive inspection of motor seals and lead wire connections to ensure a reliable power supply. “The “one-minute” emergency response mechanism has begun to show results. Guided by the principle that abnormal production fluctuations should not trigger interlocks and leaks should not lead to accidents, a comprehensive “one-minute” emergency response mechanism has been established, ensuring that emergency measures are implemented at the grassroots level and down to individual work teams. Based on the first three steps in each of the four scenarios—when key indicators begin to fluctuate, when they approach alarm values, when they approach interlock values, and when interlocks are triggered—183 “one-minute” emergency response cards were meticulously developed. A sound communication and coordination mechanism with the upstream areas of the Tarim Oil Field was established; emergency plans for fluctuations in natural gas pressure were put into effect, and abnormal situations such as frequent pressure swings during ethane recovery and the commissioning of ethylene plants were addressed promptly, ensuring that the safe production of these facilities was not affected. Organize maintenance in a high-quality and efficient manner. Following the principle of “70% preparation, 30% implementation,” quality management is integrated throughout the entire maintenance process, with strict control over the quality of maintenance for key items at every stage. At the beginning of the year, to cope with the effects of extreme cold weather, heat standby for the circulating water and steam systems was implemented for the first time during the winter period. While ensuring freeze prevention, the organization completed 37 defect-rectification and maintenance projects with zero delays, zero leaks, high quality, and no recurrence of issues. The quality of these repairs was fully verified during the plant’s startup and operation. Since September, taking into account the natural gas supply situation and assessing the impact of the pandemic, 90 winter maintenance projects worth 30 million yuan have been identified in advance. The delivery routes for materials from contractors have been optimized accordingly, ensuring that shutdown and maintenance can be carried out at any time. Achieving further improvements in quality and efficiency: Adhering to the principle of \"earning as much as possible, extracting as much as possible, reducing costs as much as possible, and making full use of available resources,\" relevant action plans and special incentive measures were introduced to mobilize everyone involved; as a result, 190 million yuan was saved in terms of quality and efficiency improvements, placing the company among the top performers among Class A units at Dushanzi Petrochemical. By intensifying market research and customer service efforts, and by focusing on the self-sales markets in southern Xinjiang, sales of functional urea increased by 418% on a year-on-year basis, pushing the company to second place in Xinjiang’s high-efficiency urea market. Seizing the favorable opportunity of rising market prices, we actively promoted product sales; the unit selling prices of liquid ammonia and urea reached record highs. Actively implement tax and fee reduction policies, revitalize idle funds, and promote the in-depth development of efforts to improve quality and efficiency. At present, all employees at the fertilizer plant are sparing no effort to enhance safe production operations, ensuring that the plant operates at full capacity. They continue to set new historical records in terms of output and efficiency, thus making further contributions to the high-quality development of PetroChina Dushanzi Petrochemical.