The simulation operation system for the carbonylation unit of Yulin’s 500,000-ton ethanol plant has been successfully put into operation

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Recently, the ethanol unit of Yulin Coal Chemical Company, part of Yan’an Petroleum, in its newly built 500,000 tons per year methanol-to-ethanol project, successfully deployed and implemented the OTS (Operator Training System) simulation operating system provided by Zhongkong Technology Co., Ltd. This important step marks a significant advance by the company in promoting the development of intelligent factories, improving employees’ operational skills, and ensuring the safe and stable operation of production processes. Traditional apprenticeship and on-site hands-on training methods have long durations, high risks, and struggle to cover all types of operating conditions, especially abnormal conditions and emergency shutdown procedures. The OTS simulation operating system effectively solves this series of problems. It incorporates the actual process characteristics, equipment parameters, and control logic of the carbonylation section in ethanol plants, thereby creating a highly faithful dynamic process model that accurately simulates the entire operating environment, from normal production to various fault conditions. Through this immersive simulation platform, operators can repeatedly practice in a highly secure and risk-free environment. The OTS simulation system enables two-dimensional and three-dimensional integration at the control room level, allowing for simulated training in dealing with various abnormal conditions such as instrument failures, equipment malfunctions, and fluctuations in process parameters. It helps employees master routine operations including the layout of on-site equipment and pipelines, start-up and shutdown procedures, adjustment of normal operating conditions, control of process parameters, and the start-up and shutdown of large-scale equipment ； The emergency drill module enhances the team’s ability to work together and respond quickly by conducting repeated emergency drills, thereby minimizing safety risks in actual production. The system also includes a module for skill assessment and evaluation, as well as a data exchange function between the instructor station and the trainee stations. This facilitates monitoring of learning progress and provides personalized guidance; it offers objective and scientific criteria for assessing the skill levels of operators, thereby contributing to the development of skilled personnel and laying a solid foundation for the pilot production of the equipment. Next, the company will continue to deepen its cooperation with outstanding partners such as Zhongkong Technology, constantly exploring the application of intelligent tools in areas such as safe production, refined management, and cost reduction and efficiency improvement, in order to push the enterprise’s high-quality development to new heights.