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Intelligence brings a new look to the management of chemical enterprises – A report on the China Petroleum and Chemical Industry Federation’s research in Yulin’s coal chemical industry. Author/Source: ChemNet. Date: December 22, 2021. Page views: 12. Last week, during its research on the digital transformation of the coal chemical industry in Yulin, Shaanxi Province, the China Petroleum and Chemical Industry Federation was deeply impressed by how intelligence enables new models for enterprise operations and management. “Digital transformation will completely change traditional corporate management concepts and models. ”Li Junjie, general manager of China Coal Shaanxi Yulin Energy and Chemical Co., Ltd., said. As the first pilot demonstration enterprise for intelligent manufacturing in the coal chemical industry, the company has in recent years innovatively implemented an intelligent optimization project for the steam, circulating water, and carbon-hydrogen ratio in methanol synthesis across the entire plant. It has also carried out optimization and retrofitting of the operating processes for facilities such as methanol-to-olefins units and gasifiers. Since the project was put into operation, it has maintained safe, stable, continuous, fully loaded, and high-quality operations for seven consecutive years, setting multiple industry records. In the shift change room of the company’s methanol facility, a large screen catches the eye. “What is shown here are the digital shift handover and intelligent inspection systems, through which employees utilize digital technology to carry out intelligent shift handovers and equipment inspections. ”Wu Xiaochen, the deputy manager of the methanol department, told the research team that they were the first in the industry to use fiber optic sensing technology to collect real-time data on factors such as vibration and temperature during equipment operation, enabling intelligent analysis and prediction of potential pipeline leaks and pump failures. They have also integrated 3D visualized factory systems with inspection systems, and connected them to data such as equipment specifications, maintenance records, process parameters, and video surveillance, thereby helping employees identify faults more quickly and improving the efficiency and quality of inspections. ““Can it be predicted in advance if internal leakage is about to occur in pipes and valves?” asked Li Bin, vice president of the Petrochemical Federation, at the scene. “Although these subtle changes cannot be directly detected, they can be sensed through fiber optic sensing via slight temperature and vibration variations. ”Li Junjie replied. “I heard that you implement a ‘four-shift, two-turn system’, where employees in each shift work continuously for 12 hours. “How can we ensure the mental well-being of employees?” asked Li Junfa, the director of the Petroleum and Chemical Planning Institute, who was standing nearby. “We adopt people-oriented management and use intelligent technologies to continuously reduce the intensity of labor. We use devices such as 5G surveillance balls, smart bracelets, or vests to enhance the safety monitoring capabilities of workers ； Establish a comprehensive analysis system for employees’ emotional health to arrange work reasonably based on their conditions. ”Li Junjie said that they have also explored new models for the operation and management of internal and external control rooms. This year, all external control rooms were moved out of the equipment area, and an intelligent inspection system is used to carry out continuous real-time inspections 24/7, thereby reducing the safety risks in those high-risk areas and significantly decreasing the number of employees as well as their workload. Even during working hours, thanks to the increased automation of the equipment and the use of intelligent inspection systems as well as DCS alarm systems, employees do not need to stay constantly on high alert in front of monitors. They can sit in the coffee area within the control room, enjoying coffee and beverages while monitoring the operation of the equipment in real time via large screens. Not long after the survey team members left the coffee shop, an instrument for detecting employees’ emotional well-being came into view. Li Shousheng, Secretary of the Party Committee and President of the Petrochemical Federation, personally experienced the test with great interest. Moments later, the test results such as his body temperature, pulse, and blood pressure were printed out. “We are also continuously driving efficiency in production management and operations through digital empowerment. ”Li Junjie added. They carry out the “431” labor competition for large teams, which generates an annual profit of 10 million yuan. The company allocated 15% of this amount, which is 1.5 million yuan, to internal market-based incentives for front-line employees, thereby greatly boosting their enthusiasm for work. At the same time, digital technologies are also utilized to explore the creation of application scenarios for advancing quality control, to develop digital models for assessing benefits, and to introduce a production model based on cost analysis. As a demonstration project for the production of ethylene via ethane cracking, the ethane-to-ethylene plant built by CNPC Lanzhou Petrochemical Yulin Chemical Co., Ltd. began operations in August this year. To date, it has produced a total of 193,300 tons of 7 different types of products, including high-density polyethylene, full-density polyethylene, and butene-1/hexene-1. In the control room of Lanzhou Petrochemical Yulin Chemical Plant, He Chao, the company’s executive general manager, told the research team that they adhere to a strategy of digital transformation and intelligent development, making comprehensive use of modern information technologies such as automation, the Internet, the Internet of Things, new types of sensors, and cloud computing to build intelligent factories with strong advantages in terms of automation, networking, digitization, visualization, modeling, and integration. Project construction follows the main threads of digital design, digital handover, and digital factory, aiming to create four integrated core platforms for operation management, production control, mechanical, electrical, and instrumentation systems, as well as safety and environmental protection. During the research, the delegation also attended a seminar on 5G applications in the chemical industry and the unveiling ceremony of a joint innovation laboratory, which were held at Shaanxi Coal and Chemical Industry Group Yulin Chemical Co., Ltd. As the largest coal chemical project currently under construction worldwide, the first phase of the company’s demonstration project on the utilization of coal to produce new chemical materials—specifically, the 1.8 million tons/year ethylene glycol project and the pyrolysis startup project—is expected to be completed and undergo trial production by late June next year. Song Shijie, chairman of the company, said that they aim to become a global leader among benchmark enterprises in intelligent manufacturing within the coal chemical industry. By utilizing technologies such as 5G, big data, and artificial intelligence, they are creating application scenarios for 5G + industrial Internet. These applications span the company’s operations, production, and control processes, enabling smart applications such as intelligent inspections, emergency command, monitoring of special operations, and remote equipment control. To date, 18 out of the 24 5G base stations planned for the entire facility have been built, and the digital delivery processes for the preliminary and detailed design phases have been completed, making it the largest digital delivery platform in China. Li Shousheng, Secretary of the Party Committee and President of the Petrochemical Federation, said that throughout human history, the chemical industry has always been at the forefront of global innovative development and transformative change. Coal chemical enterprises need to enhance their innovation capabilities for the future, boldly adopt new technologies, concepts, and models, accelerate digital transformation, build intelligent factories, and promote high-quality development.