Weihua Group records the highest monthly urea production in history

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Weihua Group’s monthly urea production reaches a record high Author/Source: Weihua Group Date: 2022-11-02 Clicks: 21 Following a monthly urea production volume of 57,166 tons in January this year, the urea production facility set another new record in October, with a production volume of 57,231 tons. Great emphasis is placed on safety and environmental protection, as well as on enhancing risk awareness. In terms of safety, the urea production workshop aims to become a company that meets first-level safety standards; by utilizing visual management techniques on site, it has carried out tasks such as anti-corrosion treatment, insulation replacement, and correction of grounding wires, resulting in a significant improvement in the visual conditions at the site. Additionally, the workshop incorporates the company’s Process Safety Management (PSM) practices and HAZOP analysis to thoroughly identify potential hazards, draws lessons from the issues identified by experts, and takes proactive actions to make necessary corrections. The workshop has revised the \"Full-Staff Safety Production Responsibility System\"; safety managers at the team leader level and above record their own performance in terms of safety duties associated with their positions, with workshop leaders conducting regular inspections. In terms of environmental protection, the urea production workshop actively cooperated and took proactive measures to support the company’s efforts to achieve an A-grade status in environmental protection, ensuring the continuous and effective operation of the environmental protection equipment. Taking advantage of the period when the system was shut down for evaporation and flushing purposes, related to urea granulation, the nozzles of the dust recovery device in the granulation tower were cleaned, and deposits on the screens and frames were removed. This approach ensured the effective operation of the exhaust gas treatment equipment in the hot and humid conditions of summer, making a positive contribution to the company’s efforts to achieve an A-grade status in terms of environmental protection. Improve the quality of inspections to completely eliminate potential hazards. The urea production plant has always placed great emphasis on the quality of inspections; in order to ensure the safe, stable, and long-term operation of the facility, the plant manager leads a team to conduct thorough inspections every Monday of the tonnage packaging line, the urea production buildings, the carbon dioxide compressor buildings, the finished product processing areas, as well as the entire plant site, ensuring no gaps are overlooked. It also insists on carrying out rectifications while conducting inspections, using inspections to drive improvements, and focusing on every aspect and detail to ensure the safe and stable operation of the equipment. In accordance with Weihua Company’s Work Plan for Stabilizing Growth in the Fourth Quarter of 2022, the urea production workshop took proactive actions to continue strengthening the basic management of production processes ； Multiple measures are taken to optimize process operations and eliminate leaks and white vapor emissions from on-site equipment. Ensure that the daily output meets or exceeds 610 tons, the monthly output is no less than 55,000 tons, and the quarterly output is at least 150,000 tons. Ultimately, achieve the company’s fourth-quarter and annual production target of “ensuring 600,000 tons, with an aspiration to reach 615,000 tons”, thereby fulfilling the goal of attaining tangible results in our work. To implement energy conservation and carbon reduction and ensure synergistic effects, the urea production plant has earnestly carried out the company’s plan for \"energy conservation, carbon reduction, water savings, emission cuts, and synergistic improvement.\" An organizational structure was established, with responsibilities assigned at each level to specific individuals. Details have been provided in terms of safety and environmental protection, process and equipment management, as well as power and water conservation; significant results have been achieved especially in power conservation, with the electricity consumption per ton of urea produced by the urea plant remaining below the set targets for three consecutive months. The workshop takes a management-oriented approach to shift from a passive to an active stance, ensuring product quality while also maintaining urea production levels. First, the \"Urea Product Quality Control Plan\" was revised and improved; key stages were identified, and quality control during post-packaging as well as distribution and marketing processes was strengthened. Secondly, the domestically produced granulation nozzles have been successfully tested, **reducing the delivery time for these nozzles as well as their purchase cost ； Third, routine maintenance was strengthened to overcome the challenges posed by increased workloads; the switching frequency of the granulation nozzles was increased. Meanwhile, the inlet filter of GA201 was modified to improve its sealing performance and prevent urine from taking a short circuit. Increasing the output of tons of packaged urea to meet market demands: Of the monthly urea production of 57,231 tons, the monthly output of tons of packaged urea also reached a record level of 5,401 tons. Recently, due to a sudden surge in market demand for ton bags, the urea workshop specifically formulated the “Quality Control Plan for the Urea Production Process”. It requires all technical personnel, team leaders, and central control operators to continuously improve their operational skills, so as to ensure that the rate of high-grade urea products meets the standards and to guarantee the quality of ton bag products. To meet the demand from the sales market for urea in ton bags, the workshop has asked the staff working on the ton bag production line to work overtime to ensure that tons of urea are shipped out daily. Urea is one type of diversified urea-based products. It serves as a key means for the group company to mitigate internal and external risks and meet market demands. Achieving product diversification enables the company to establish a solid foothold in today’s market and product landscape, thereby ensuring its continued survival and growth ； When the existing products or market scope is limited, product diversification allows a company to find new sources of growth in other products or market areas, thereby compensating for losses and achieving a stable and effective pattern of development.