New breakthrough achieved in the long-cycle operation of SE Dongfang furnaces by Zhongan United

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New breakthrough achieved in the long-term operation of SE Dongfang furnace at Zhongan United / Author/Source: Zhongan Coal Chemicals / Date: 11-01-2021 / Clicks: 1 On January 5, East China University of Science and Technology and Sinopec Ningbo Research Institute sent a congratulatory message to Zhongan United, celebrating the fact that the A-grade continuous operation of a single furnace in the gasification unit SE Dongfang had exceeded 210 days, while the nozzles had accumulated a total operating time of over 370 days. The gasifier is the most critical equipment in coal chemical production and the core of the coal gasification unit. To date, dozens of types of gasifiers have been used both domestically and internationally. Among them, the dry coal powder gasifiers that are most commonly used include SHELL, GSP, and the Aerospace Gasifier, among others. The main indicators used in the industry to assess the performance of gasification furnaces include specific coal consumption, specific oxygen consumption, cold gas efficiency, and wastewater discharge volume, among others; however, the continuous operation cycle is one of the most important of these indicators. Among the various types of gasifiers, those capable of operating continuously without interruption (Class A) for more than 200 days are rare; many coal chemical companies need to make strenuous efforts over 5 years, 10 years, or even longer to achieve this. It took only one and a half years for the SE Dongfang furnace of the Zhongan United gasification unit to go from starting coal feeding tests with its first gasifier on June 15, 2019, to achieving a record of 210 days of continuous operation at Class A performance per furnace. Where it takes others years of effort to reach such a level, Zhongan United achieved it in just one step; the operating cycle of its gasification furnace is on par with the best standards in the country. This has set a new benchmark in the industry for continuous, stable operation at high loads over long periods of time right from the moment the new type of gasification furnace is put into use. The SE Eastern Furnace coal pressurized gasification technology was independently developed by Sinopec and East China University of Science and Technology. Based on a comparison of gasification technologies both domestically and internationally, Zhongan United took on the responsibility of carrying out industrial demonstrations of domestically developed technologies, thereby enabling the large-scale industrial application of these independently innovated technological achievements for the first time at Zhongan United. To ensure the stable operation of the SE Oriental furnace, Zhong’an United, in collaboration with the design unit, actively identified the factors hindering its stable operation in addressing the challenges related to the large-scale clean and efficient gasification of “Huainan coal,” which is characterized by high ash content and a high ash melting point. Continuous technical research was carried out, resulting in the resolution within a relatively short period of multiple technical bottlenecks and problems, including a high rate of ignition failures, leakage in the sealing of the annular space, damage to the water-cooled walls of the lower conical section, and poor scrubbing efficiency of the syngas. At the same time, Zhongan United strives to keep up with industry best practices by adopting a routine of \"daily optimization, weekly analysis, and monthly summarization\" to prepare reports on abnormal operating conditions. It strengthens the management of coal quality used in the furnace as well as the risk assessment and control related to changes in coal types. The company carries out preventive maintenance on key equipment, standardizes the maintenance procedures for such equipment, and establishes a standardized maintenance system for gasifiers. These effective daily practices have led to an improvement in the overall stability of gasifier operation, laying a solid foundation for the steady, full-capacity operation of the gasification unit over extended periods. They also ensure that the performance indicators of this gasification unit can reach international leading levels in a relatively short time. The long-term stable operation of the gasifier in the Zhong’an United gasification unit marks a success in the large-scale industrial application of SE Dongfang’s pulverized coal gasification technology. It has enabled a historic transformation of \"Huainan coal\" from a traditional fuel to a chemical raw material, opening up new ways for its clean and efficient utilization. This development serves as a catalyst and example for promoting the economic transformation in the region.