Xintian Coal Chemical: Two minor upgrades result in annual savings of nearly 5 million yuan

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Xintian Coal Chemical: Two minor renovations result in annual savings of nearly 5 million yuan. Author/Source: Zhejiang Energy Xintian Coal Chemical. Date: 2021-12-20. Clicks: 5. After the renovation of the condensate pipelines in Xintian Coal Chemical’s conversion unit, significant improvements were achieved in terms of safety and economic efficiency, meeting the expectations set initially. Each unit of this conversion device can recover 10 cubic meters of condensate per hour; over the course of a year, it can recover a total of 100,800 cubic meters of condensate, which helps to save more than 3.528 million yuan in costs. Since its commissioning, the shift unit in the gasification workshop of Xintian Coal Chemical Industry has generally met the expected objectives. However, it has also been revealed that due to design issues, the condensate from the shift steam cannot be properly fed into the main condensate pipeline; as a result, it has had to be discharged on-site. In winter, a thick layer of ice forms on the ground, posing a risk of falls and slips for the personnel on site. These issues not only affect safety during production operations but also lead to significant waste of condensate. To address this challenge, the members of the company’s gasification plant’s “Five Small Projects” team proposed boldly that, by taking into account the operating pressure of the deoxidation station, the condensate from the heat tracing steam used in that unit could be incorporated into the deoxidation station, with this condensate being used in place of desalinated water; this approach would thereby reduce the amount of desalinated water required. Through water quality analysis of the condensed steam, the silica content, conductivity, and pH value in the water all meet the requirements for boiler water quality, satisfying the water requirements of the deaeration station. At the same time, taking into account the layout of the process pipelines on site, the project team proposed once again to create a branch at the end of the condensate main pipe on the third floor and connect it to the deaeration station; this approach not only results in shorter pipeline modifications but also reduces costs. After a series of modifications and once put into use, it achieved the desired results: it fundamentally resolved the problem of excessive waste of steam tracing condensate, and at the same time eliminated the safety hazards present in the production process. Efficient recovery and reuse of lubricating system oil. Recently, another renovation project for the pressurized gasification unit at Xintian Coal Chemical Industry was put into operation; the work to recover and reuse the lubricating oil from 22 gasifiers has been fully completed. After half a month of debugging, this renovation achieved the expected results. It is estimated that the 22 gasifiers can save nearly 200 barrels of No. 6 synthetic superheating cylinder oil per year, resulting in economic benefits of over 800,000 yuan. During operation, the company’s pressure gasification unit suffers from excessive pressure in the lubrication system’s oil injection pump circuit, which often causes the safety valve in that circuit to activate temporarily, leading to the leakage of lubricating oil into an external collection tank. This phenomenon leads to severe contamination of the lubricating oil, making it impossible to recycle and reuse it, thus resulting in serious waste of lubricating oil. In response to this issue, members of the company’s gasification plant task force proposed installing a plastic tubing with a diameter of 10 millimeters at the relief valve outlet of the lubrication system’s oil injection pump, leading it to a clean oil tank where it could be stored in a sealed condition. When the overflow tank is full, contact the relevant personnel to take samples for analysis. If the analysis shows that the oil is not contaminated, it can be recovered and reused. It is understood that the oil pipes and fittings used in this renovation were all materials stored in the company’s warehouse, with a total cost of 3,000 yuan, achieving a high return on low investment. Throughout the years, Xintian Coal Chemical has always adhered to the production philosophy of reducing costs and increasing efficiency. The various production units have continuously optimized and innovated the processes in place, truly putting energy conservation and emission reduction into practice. Everyone contributed their ideas, offering valuable suggestions for the company’s development, and ensured that small inventions, innovations, improvements, designs, and recommendations were integrated into all aspects of work. By focusing on improving production quality, the company promoted its high-quality development.