Luchi and Shell furnaces of Lu’an Group are operating continuously and stably, setting new world records

Thread Content

The Luchi and Shell furnaces of Lu’an Group are operating continuously and stably, setting new world records. Author/Source: Yahuacoking Chemical Industry. Date: 2019-07-08. Clicks: 17. Gasification technology is a key method and essential component for the clean conversion of coal. On July 3, 2019, Lu’an Coal-based Synthetic Oil Company received another piece of good news: a single Lurgi gasifier was able to operate continuously and stably for 230 days under complex coal quality conditions, once again setting a new industry record for the continuous and stable operation of Lurgi gasifiers. On the same day, G1 gasifier of Lu’an Clean Energy Company – the world’s largest coal-fed gasifier with a capacity of 3,000 tons per day – operated continuously and stably at high load for 210 days, setting the best initial operation record for gasifiers of this type in the industry. The continuous and stable operation of the Luchi furnace and Shell furnace dual-generation equipment has set new industry records, marking a new breakthrough by Lu’an Group in its pursuit of disruptive energy technologies, as well as new achievements in accelerating the development of bases for the transformation of coal-based scientific and technological achievements. This is also the latest example of Lu’an’s efforts to promote the development of the enterprise through self-reform, by continuously strengthening its awareness of self-revolution, since the launch of the theme education campaign aimed at \"remaining true to our original aspirations and keeping our mission firmly in mind\". I. Pursue breakthroughs through technological innovation and strive for excellence in management; Luchi gasifiers set new records for integrated operation in the industry. The Ruchi gasifier operated continuously and stably for 230 days, representing yet another successful demonstration by Lu’an Coal-based Oil Company in line with Lu’an Group’s strategic goal of building a leading enterprise in the modern energy and chemical industry through high-quality development. By continuously adjusting the production processes, optimizing the ratio of coal used, and maintaining precise operations, the company was able to exceed a daily oil production volume of 530 tons once again, following its achievement from last year. First, actively carry out research and efforts to upgrade gasifier technology. Through the \"three types of renovations\" to the gasifier equipment system – technical improvements to the sealing surfaces of the upper and lower valves in the ash lock, the innovative use of castables in combination with lump charcoal in the gasifier, and optimizations to the gasifier’s grate system and moving components – the bottleneck issues encountered during the operation of the gasifier were successfully resolved. At the same time, technical improvements such as modifications to the ash lock limit mechanisms, the steam pressure measurement pipelines feeding into the furnace, the pipelines used for flushing ash steam, and the spray water systems in the dust collectors were carried out, which effectively reduced the incidence of equipment failures and greatly improved the overall operational stability of the gasification furnace equipment. Second, strengthen the maintenance and inspection of on-site equipment. An equipment management model featuring \"programmed inspections, tabulated maintenance tasks, visual management, and standardized operations\" has been established. By combining programmed inspections with regular specialized maintenance, this inspection approach helps to reduce shutdowns caused by inadequate inspection and maintenance efforts. In terms of equipment inspection, meticulous operation and maintenance as well as inspections of the equipment are carried out to ensure thorough inspection without any blind spots; equipment management records are established to detail operational data, allowing for long-term tracking of changes in the equipment’s performance. In terms of equipment maintenance, efforts are made to actively identify and eliminate potential safety hazards in the gasification furnace system, with the aim of preventing accidents from occurring in the first place. By addressing issues promptly, potential risks of unplanned system shutdowns in the gasification furnace were successfully avoided, thus preventing such unplanned stops. Strive to strengthen process control over the quality of maintenance work, ensure compliance with equipment maintenance standards, and further optimize and improve all systems of the equipment. Third, continuously optimize and adjust process parameters. Through systematic process adjustments, continuous experimentation, and the ongoing collection of comparative data, efforts were made to identify the optimal operating parameters, resulting in numerous significant and innovative attempts to improve the stable operation of the gasification furnace. The steam-to-oxygen ratio in each gasification furnace decreased from 5.55 Kg/Nm3 in 2018 to 5.37 Kg/Nm3, enabling more complete reaction of the raw coal in the gasification furnaces. The concentration of useful components in the raw gas continued to increase, with the CO content rising from 24% to over 25%. At the same time, by optimizing external systems to adjust the pH value of gray water in a timely manner, corrosion and erosion in the pressure relief pipelines of gray lock systems were reduced. Fourth, strengthen the monitoring and proportioning of coal types fed into the furnace. While continuously improving fuel management, supervision over the blending of coal types is strengthened to increase the rate of successful blending. Different blending schemes are formulated based on the quality of the coal in stock and the load of the units, and coal quality test results as well as the blending process are monitored in real time, allowing for timely adjustments to optimize the ratios. This has improved the quality of coal fed into the furnace, ensured that it meets the required standards, and led to an overall upgrade in management practices, providing a solid foundation for the stable operation of the gasification furnace. II. Strive for innovation to reach new heights, implement strict, meticulous, and effective management; Shell’s gasifier set a record for successful commissioning and operation from the very beginning. On July 3, 2019, G1 gasifier of Lu’an Clean Energy Company – the world’s largest coal-fed gasifier with a capacity of 3,000 tons per day – operated continuously and stably at high load for 210 days. This achievement set a new record for the best initial operation performance among Shell gasifiers of this type, as well as representing a case of long-term operation right from the start, a phenomenon that has never been seen before in the history of Shell gasifier operations. Currently, the 4 gasifiers of the Lu’an 180 project are operating stably. At the same time, this breakthrough also marks new achievements in the platform for exchange and cooperation on the energy revolution established jointly by Lu’an and the American company AP, pushing cooperation with multinational companies in this area to a new level. When Furnace G1 had been in operation at Grade B for 175 days, Peng Zhe, a senior expert from Shell Gasification (now AP Syngas Technology Development Company), and Dr. Qu Qiang, the head of Gasification Technology Development Company, sent a congratulatory message to Lu’an Coal-based Clean Energy Company. They celebrated the 175 days of operation of Furnace G1 at Grade B, as well as the 126 days of operation of Furnace G2 at Grade A earlier on, stating that this level of operation represented the best record to date for initial operations of Shell-type furnaces of this kind. The performance achieved in the first year of operation was equivalent to what other plants of the same type would take at least three to five years, or even longer, to attain. Given the operating characteristics of Shell’s gasifiers, what specific and effective measures has Lu’an Coal-based Clean Energy Company, which is responsible for the construction and operation of the 180 project, taken? First, ensure quality at the source by focusing on the coal used in the furnace. Mixing multiple coal types to expand the operating range of the gasifier. Currently, based on the design of coal types, the company has successfully mastered and applied various binary and ternary coal blends (including the use of high-sulfur coal). It reduces costs while also expanding the operating range of the gasifier, thereby minimizing the risk of slag and ash buildup. At the same time, great emphasis was placed on ensuring the stability of coal sources and coal quality; by implementing measures such as rapid testing of incoming coal and monitoring of the coal blending curve, the basic conditions for long-term operation were fundamentally met. From January to June 2019, the content of useful gases in the raw gas exceeded 91%, an increase of about 10% compared to 2018, resulting in a significant reduction in consumption per unit volume. Second, focus on process control and make efforts in safety management. Safety inspectors are assigned to conduct regular on-site inspections to ensure comprehensive oversight. Greater attention is given to the inspection and maintenance of key parts of the gasification furnace, and any areas with safety hazards are rectified. This approach shifts focus from dealing with problems after they occur to taking preventive measures in advance, thereby achieving closed-loop management of safety hazards. Third, practical measures should be taken in emergency response, with efforts focused on adapting to changes. Coal-based clean energy companies are continuously strengthening the development of a coordinated management system for joint ventures. Through \"information sharing, resource exchange, technical cooperation, and mutual support in management,\" they work together to overcome challenges, develop appropriate emergency response plans to address the issues and risks associated with the operation of gasification furnaces, and respond promptly to any changes or emergencies that occur on site. Fourth, start by optimizing the system processes and focus on improving production operations. To completely resolve the issue of inlet blockage in the compressor during its later operational phase, the structure of the inlet filter for the circulating gas compressor K1301 was modified. Optimize process parameters, such as reducing the SGC inlet temperature and increasing the K1301 inlet temperature, and use furnace temperature parameters like heat load and water vapor density to more accurately reflect the operating conditions of the gasifier, thereby guiding process adjustments. Adjust the control strategies for key equipment; for example, modify the backwashing cleaning strategy of the high-temperature and high-pressure fly ash filter S1501. By implementing intermittent backwashing based on different load conditions, the service life of the filter elements can be extended. Through technical improvements to optimize the anti-surge system of the CO2 compressor, the operation of the compressor was stabilized, and a stable supply of CO2 gas was provided for use in the gasification furnace. The nitrogen content in the system decreased from 2% to around 1%, reducing the nitrogen content in the purified gas and thus laying the foundation for increased oil production in the downstream Fischer-Tropsch synthesis unit. In the future, as the energy revolution in Shanxi Province progresses further, and Lu’an Group establishes coal chemical processing as its new core business, new coal chemical technologies will continue to emerge and see advancements on Lu’an Group’s journey to become a leading enterprise in the modern energy and chemical industry characterized by high-quality development. Technological innovation will become widespread, leading to a situation in which such innovations flourish everywhere. The groundbreaking advances in Lu’an’s gasification technology will undoubtedly contribute to China’s energy transformation and upgrading, and will provide more of Lu’an’s experience and insights for the pilot projects related to the energy revolution in Shanxi.