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Zhongyuan Dahua Methanol Division: Technological upgrades and innovations to solve problems Author/Source: Zhongyuan Dahua Date: 2021-07-19 Clicks: 3 “I never expected that a simple technological upgrade could resolve the issues associated with the operation of coal mills during heavy rainfall. It not only reduced the operational difficulties for control room staff and those on site, but also increased the safety level of the plant’s operations in extreme weather conditions.” ”Looking at the coal grinder operating smoothly before them, the workers at the gasification plant of the methanol division said happily. This weekend, Puyang will experience heavy rainfall once again. The technical upgrades to the coal grinding machines were put to the test during these heavy storms, and the results were satisfactory – the coal grinding load did not decrease as a result of the stormy weather! Recently, extreme weather conditions have become increasingly frequent in Puyang City, with rainfall amounts reaching new highs. The problem of the gasification coal grinding system being unable to operate continuously under such extreme weather conditions has become more apparent. Especially during short-term thunderstorms with heavy rainfall, or when strong winds are accompanied by prolonged periods of rain, the increase in system pressure prevents the gases generated from being discharged steadily and continuously, forcing the coal grinding system to reduce its operation capacity or even shut down. This results in low levels of coal powder in unit 12, affecting the continuous operation of the gasifier and forcing it to reduce its capacity, or even leading to the shutdown of the entire gasification system. This issue has plagued the gasification unit for many years; in particular, the two heavy rains in June and July caused significant difficulties in the proper operation of the coal grinding system, thereby posing a serious challenge to the safe, stable, and long-term operation of the gasification unit. In order to overcome the adverse effects of the natural environment and break free from the passive situation of relying on weather conditions for survival, on July 12, the gasification plant invited Liu Hongyu, General Manager of the Technical Management Department of the park, Guo Jianfeng, General Manager of the Methanol Division, along with Deputy General Managers Zhang Hongfei, Wang Lin, and Zhang Weishan, as well as key technical staff from the gasification plant, to hold a video conference for analysis. In response to sudden extreme weather conditions that affect the coal grinding system, a detailed analysis of the associated phenomena and their causes was conducted, along with thorough and bold discussions, aiming to propose tentative solutions. After finalizing a tentative reform plan, the gasification plant overcame various difficulties, defined clear responsibilities, conducted a thorough analysis of the risks associated with the process steps and operational procedures outlined in the plan, and refined and optimized the feasibility and safety aspects of the construction plan. To ensure safety during the operation process, the operational environment is simulated in advance; after a fire hazard analysis is conducted by the center’s laboratory, the safety aspects related to the system’s handover as well as the associated welding operations are re-evaluated, thereby determining the final plan for handover and construction. While ensuring the safety of the equipment, the gasification plant is carrying out the renovation plan in an orderly and diligent manner. At around 9 a.m. on July 15, coal mill A1101B was shut down, and process engineers promptly began carrying out comprehensive maintenance work on the B-series coal milling system. At 11:07 a.m., as the cutting machine generated bright sparks, it marked the official implementation of the gasification plant’s experimental modification plan for the coal milling system under extreme weather conditions; tasks such as making openings in the pipes of the coal milling exhaust system, adding additional connections, laying discharge pipes, and conducting process adjustments were subsequently completed. Technological innovation is the driving force behind corporate development. By taking into account the actual conditions of production, gasification plants proactively address existing problems, take initiative rather than waiting passively, and explore new solutions. This approach not only helps to overcome the challenges that hinder safe production but also fosters innovation, contributing to the safe and stable operation of coal chemical facilities.