Revealed! What ‘cutting-edge technologies’ do central control systems rely on to power the key components of gasification furnaces?

Thread Content

Included in the topic: During the start-up and shutdown processes of traditional ammonia synthesis gasifiers, high temperatures, high pressures, complex processes require precise operation; moreover, peroxides can explode, posing risks that directly affect the success rate of these operations. Therefore, how to improve the success rate of start-up and shutdown processes and reduce losses in terms of resources and personnel is the primary issue that needs to be addressed in the intelligent transformation of chemical plants. The current start-up and shutdown procedure for the gasification furnace unit is as follows: Initially, operation training and responsibility allocation are carried out through paper-based SOPs ； During the process, the operator follows the standard procedures as described in the written instructions ； After completion, sign on the paper SOP. In this process, operators inside and outside the facility communicate via wireless walkie-talkies to keep track of their respective operations and progress. This approach presents a range of issues, including a large amount of paperwork required for signing, easy oversights in version synchronization, high barriers to operation, missed or incorrect actions, difficulties in storing and tracking information, slow query and verification processes, and challenges for those outside the facility in obtaining instrument data. The central control technology operation navigation solution was developed specifically to address the aforementioned issues, and it can significantly improve the convenience and accuracy of both the configuration process and the operation process. Even process engineers without expertise in automatic control can carry out the configuration process using graphical programming on a computer-based interface; by simply dragging and dropping components from a component library, they can convert paper-based SOPs into electronic form. During the operation process, especially during startup and shutdown, the internal operators can monitor things via the computer, while the external operators carry out the actual operations using mobile devices, thereby enabling coordination between internal and external operations throughout the entire process. Effects of the gasifier renovation: After applying a central control technology and operation navigation solution to the key components of a gasifier in a certain project, paper-based SOPs were converted into electronic forms, enabling programmed operations. Mobile devices were used to facilitate coordination between operators on-site and those in control rooms. This approach not only increased the success rate of starting up and shutting down the gasifier but also brought about the following improvements: 1. Through programmed, standardized controls, a system of \"sign-off after each step\" was implemented for operator actions, which significantly reduced the workload and led to a notable reduction in errors ； 2. Process engineers can configure settings directly on the graphical interface; compared to traditional DCS sequencing programs, no coding is required, which reduces training costs ； 3. Structured flowcharts can provide a more intuitive representation of the manufacturing process, thereby reducing the training time required for staff ； 4. Operators receive more informative real-time guidance and can access additional information on their own, reducing the technical barriers and significantly improving the efficiency of on-site operations ； 5. Operators can directly synchronize process information via mobile devices, reducing the frequency of communication using walkie-talkies ； The start-up and shutdown processes are visualized, reducing the number of screen clicks required by operators by 70% ； 6. Electronic SOPs are updated in real time, preventing missed steps due to version inconsistencies; moreover, paperless operations help reduce operational costs ； 7. The digital storage function facilitates data archiving and traceability, laying the foundation for future data interoperability ； 8. Provide a path for gradual automation upgrades, and through process improvements, achieve truly fully automated operations. Today, industrial enterprises are moving toward liberating people from their work, standardizing people’s management, and reducing the impact of humans. In the process of digital and intelligent transformation of industrial enterprises, in order to address practical challenges in various scenarios, a variety of application software is needed to enable industrial equipment to function intelligently, and operation navigation software is one such tool. The central control technology operation navigation solution is based on operation navigation software and utilizes mobile devices as a platform to overcome spatial limitations. By enabling data interconnection, it facilitates transparent visibility of production processes and collaborative work, thereby creating digital versions of standard operating procedures as well as human-machine collaboration. On the path ahead, Zhongkong Technology will continue to uphold its vision and mission of \"making industry smarter and life easier,\" striving to create more value for its customers and moving forward together.