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The Chemical Technology Development Department of Shaanxi Chemical Industry achieved significant results in 2021. Author/Source: Shaanxi Chemical Industry. Date: 2022-01-27. Clicks: 17. In 2021, Shaanxi Chemical Industry made concerted efforts to advance the construction of key projects, and actively worked to resolve challenges related to production processes as well as technical bottlenecks. Over the past year, the team has taken the lead in implementing 9 key company projects, including improvements to the energy efficiency of ammonia synthesis units, the construction of smart factories, optimizations to the internal components of gasification furnaces, and enhancements to the performance of the 1,4-butyndiol production system. They have also organized 112 technical renovation projects across various departments; 16 patents have been granted, and a total of 5 technical achievements have been recognized with awards for scientific and technological progress by the China Nitrogen Fertilizer Industry Association and the Shaanxi Chemical Engineering Society. All these efforts have effectively contributed to improving the company’s operational standards and have played a positive role in promoting its high-quality development. Focus on improving quality and efficiency, and strengthen support for high-quality development. Make improving quality and efficiency the core task of the department, and steadily advance the implementation of three key projects: improving the energy efficiency of ammonia synthesis units, optimizing the internal components of gasifiers, and enhancing the performance of the 1,4-butyndiol production system. The energy efficiency improvement project for ammonia synthesis plants recovers and purifies the liquid nitrogen-based purge air, which was originally designed for suboptimal use, so that it can be utilized further in subsequent ammonia synthesis processes. By optimizing the shift converter, low-temperature methanol wash unit, liquid nitrogen wash unit, and ammonia synthesis plant, as well as adding a new exhaust gas shift converter, the production capacity of the ammonia synthesis plant has been increased; the capacity per unit has risen from 1,200 tons per day to 1,300 tons per day. The overall optimization effects are expected to become apparent after the major maintenance in 2022. Optimizations were made to the internal components of Furnace D for gasification, upgrading the Texaco furnace to the Jinhua furnace process. The equipment modification was completed in October, with mechanical completion scheduled by the end of December. Upon integration into the system, it is expected that the gasification furnace will be able to operate continuously for over 100 days, while also generating 3 t/h of medium-pressure steam as a by-product. The project to improve the efficiency of the 1,4-butyne diol production system involves adding an additional acetylation reactor along with supporting facilities, which are connected to the existing production equipment. This helps to stabilize the production capacity of 1,4-butyne diol and its downstream products, reduces the operational load on the equipment, and enhances its operational stability. At present, the waste catalyst storage tanks and bundle filter units have been largely installed. Due to the catalyst replacement in the production system, pile foundation construction is underway for the main reactor frame; meanwhile, key optimization efforts such as improving acetylene purification efficiency, enhancing BDO quality, and upgrading BYD purification processes are also being carried out. Focusing on intelligence and digitalization to stimulate high-quality development, and in response to the needs of enterprises for digital and intelligent upgrades, as well as taking into account the technological trends in the industry, a \"Status and Needs Analysis Report\", a \"Master Plan Report\", and an \"Overall Design Plan\" for the smart factory were prepared. These plans were approved by the group company in April, laying the foundation for the construction of the smart factory. At present, the first phase of the smart factory project is being carried out in an orderly manner; the bidding process has been completed for the infrastructure network, data center facilities, basic resources and the industrial Internet platform, as well as the BDO personnel positioning system. Optimizations have been made to ensure compatibility with real-world application scenarios; an intelligent access control and monitoring system that meets the requirements of the \"Technical Guidelines for Emergency Management of Mobile Sources in Industries Affected by Severe Air Pollution\" has been developed. This system enables the scheduled approval of freight vehicles, as well as provides video surveillance throughout the entire process from when vehicles enter the facility to when they leave it. It has been adopted by environmental protection agencies as a model for access control systems. By utilizing big data analysis, Internet of Things technology, and intelligent control technologies, the packaging line for urea products is upgraded to be more intelligent; experimental devices for intelligent storage systems are developed, thereby establishing a benchmark for intelligence in this industry. The packaging line upgrade for the current warehousing system has been completed, resulting in a 25% increase in the packaging volume per hour per system, with a product inspection rate of 100%. The intelligent storage shelves and transfer systems have begun trial operation. The APC intelligent control renovation of Boiler 3# enables closed-loop system control; the system can respond automatically, promptly, and accurately to changes in external load, effectively reducing interference between boilers, suppressing their natural vibrations, and narrowing the range of fluctuations in their performance parameters. After the system was put into operation, it increased the coal savings rate of Furnace 3 by more than 0.5%. Efforts are made to stabilize production, overcome challenges, and build momentum for high-quality development. Ensuring that the system’s production operates on a continuous basis, at full capacity, safely, stably, and efficiently is regarded as the core task of the department; technical solutions are sought to address production-related technical challenges and meet the needs of operations. A new No. 9 cooling tower was added to the 450A circulating water system, resulting in a reduction of approximately 1.5°C in the water temperature entering the system compared to the same period last year. The addition of the 5# ball mill to the phosphoric acid ammonium system ensures stable operation of the phosphoric acid ammonium production facility and helps release its production capacity. The exhaust gas scrubber for the Phosphoric Acid I system was designed independently to ensure that the emissions from the system meet all relevant standards. The upgrade of the 520,000-ton urea packaging building has significantly improved the cleanliness and aesthetics of the site. The newly designed coloring tank for the phosphate ammonium plant has been installed ； The procurement of major equipment for the phosphorus ammonium phosphate ore storage expansion project has been completed ； The detailed design for the new waste sulfuric acid tank for phosphatic ammonia production has been completed; the bidding process for selecting the construction contractor is currently in progress ； The plan for the flue gas generation tower in phosphatic ammonium has been finalized, and the equipment bidding is complete. Construction has begun on the rainwater collection tank for the old fertilizer plant, designed for the urea production facility ； Equipment procurement is underway for dust removal in the 1# and 2# urea packaging buildings. The automatic dosing device for Boiler No. 3, customized for the Power Plant Branch, has arrived and will be installed at an appropriate time ； The DCS upgrade project for Furnace 3# is ready for shipment ； Equipment procurement is in progress for the boiler flame detection system ； The equipment for the 2# furnace energy efficiency improvement project has arrived, and it is planned to be installed during next year’s major maintenance period. The pneumatic ash conveying project for Dust Collector No. 5 implemented at the BDO branch plant has now seen the completion of equipment procurement, with detailed design work currently in progress ； A plan has been finalized for the renovation of the dust collector in the calcium carbide storage and transportation system, and equipment procurement is currently in progress ； The design for the new activated carbon filter has been completed, and equipment bidding is currently in progress. The foundation for the new BDO P8201 pump designed by the Mechanical Power Department, along with the plan for replacing the BDO underground pipes, has been successfully implemented. The water seal tank for the waste methanol storage tank, designed in collaboration with the Ministry of Safety and Environmental Protection, has been successfully put into operation ； The design of the four hazardous waste storage facilities has also been completed. In collaboration with the Mechanical Power Department and the Production Technology Department, a technical upgrade was carried out on BYD’s feed pumps; by coating the piston surfaces with tungsten carbide, the service life of the pistons was extended to 5–6 months ； At the same time, the surface of the plunger rod is coated with carbides, extending its service life by 2-3 times compared to before. In 2022, the Department of Science and Technology Development will continue to strive toward the vision of becoming a first-class chemical enterprise characterized by employee well-being and mutual respect. Focusing on the key areas of increasing production capacity, improving product quality, enhancing management efficiency, and accelerating innovation, it will strengthen its sense of responsibility, draw lessons from past experiences, improve its overall capabilities, and carry out all tasks as usual in order to make greater contributions to the high-quality development of the enterprise.