Baling Petrochemical: Gasification unit sets world record for longest annual operation time among similar units

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Baling Petrochemical: Gasification Unit Sets World Record for Longest Annual Operation Time Among Similar Units Author/Source: Sinochem News Network Date: 2021-01-21 Clicks: 30 Recently, Baling Petrochemical reported that in 2020, the gasification unit under its coal chemical division overcame two major challenges in this industry: the failure of the slag crusher’s blades and the downward movement of the hot zone in the gasification furnace. As a result, the unit was able to operate at high load levels for extended periods, running for a total of 350 days throughout the year. This achievement set a world record for the maximum number of days a single shell gasification furnace can operate in a year, with an average annual operation rate of 94.15%. The unit’s operational performance was the best ever recorded. Over the years, Baling Petrochemical has been committed to researching the bottleneck issues that affect the stable, efficient, and optimal operation of Shell’s powder coal gasification unit. Through relentless efforts, by establishing standards for coal procurement and quality control of coal fed into the furnace, as well as by optimizing the operation of the gasification furnace, this device has now achieved regular operation for over 150 days in a row. However, as the consecutive operation days increased, the gasification furnace encountered a new \"bottleneck\" – the downward shift of the hot zone. When the gasification furnace operates continuously for 100 to 120 days, an abnormally high temperature in the lower part of the furnace chamber occurs, accompanied by the shedding of slag from the slag screen. The falling of large slag pieces not only increases the risk of slag blockage in the system but can also lead to the shutdown of the equipment in severe cases, and may even cause damage to the bottom cone of the gasification furnace. In the past 5 years, the \"downward shift of the hot zone\" has become a persistent and serious problem plaguing similar devices in China. In late March 2020, severe fluctuations occurred in the slag system of the pulverized coal gasification unit at the Coal Chemicals Department, resulting in 4 out of 8 slag breaker blades falling off one after another. The Party branch of this facility called on all staff to focus on the goal of \"setting new records.\" All Party members took the lead by working in shifts 24/7, strengthening the capabilities of the process teams, preventing the formation of large slag masses within the system, and removing slag promptly. This ensured the continuous operation of the facility, making it the first facility of its kind, both domestically and internationally, to maintain high-level operations even after the slag removal machines were shut down. On April 11, 2020, after operating continuously for 133 days, the device experienced a phenomenon of \"downward movement of the hot zone\"; coupled with the fact that the slag breaking machine could not function properly, the risk of the gasification furnace stopping due to slag blockage was extremely high. In response to this, the gasification technology team, through in-depth research, finally identified the direct cause of the \"downward shift of the hot zone\". Through a series of measures such as optimizing the coal mixture fed into the furnace, the phenomenon of \"downward movement of the hot zone\" was effectively controlled. It is understood that in the process of overcoming the bottlenecks in gasification facilities, Baling Petrochemical has obtained multiple invention patents, including 4 technical invention patents and 2 utility model patents. From 2018 to 2020, the unit achieved three consecutive periods of Class A operation lasting over 200 days each, thus becoming the first in the industry to enter a new phase where continuous operation for more than 200 days became the norm. The operation cycle of the facility, along with its technical and economic indicators, are at the leading level among similar facilities worldwide, resulting in significant economic and social benefits.