BDO Branch: The Right Time to Increase Production and Efficiency – Strive for Excellence and Take the Lead

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BDO Plant: The Right Time to Increase Production and Efficiency – Striving for Excellence and Taking the Lead. Author/Source: Shaanxi Chemical Industry. Date: 2022-01-27. Clicks: 13. In 2021, Shaanxi Chemical Industry’s BDO plant saw a 15.2% increase in BDO production on an annual basis, while PTMEG production increased by 17.5%. The monthly BDO output reached 12,100 tons, and the capacity of the first-phase alkyne production unit increased by 15% – all of which represented record levels. Throughout this year, the entire plant focused on eliminating \"inherent violations,\" implemented strict controls over permits and documents, and improved oversight of on-site operations. At every maintenance site, chemical industry professionals were required to be present to supervise the work and monitor its progress, while specialized staff conducted random checks to ensure that the relevant permits and safety measures were properly followed. With the involvement of all staff, HAZOP analyses of the production facilities will be carried out in greater depth. The findings of these analyses will serve as the focus of safety and environmental protection training, which will be conveyed to all employees. Strictly adhere to the design specifications for raw materials entering the plant as well as national standards, in order to control the quality of materials at the source. Replace the instruments that affect the hydrogenation reaction, aim to meet the standards of leading companies in the same industry, and analyze material balance sheets in detail. Focus on controlling key process parameters related to hydrogenation, such as the hydrogen circulation rate, reactor pressure difference, and formaldehyde concentration. Analyze changes in DCS data and inspect equipment and pipelines on-site, so that the butanol content remains below 1.5% within two months after replacing the hydrogenation catalyst. Continue to explore the potential of the first-stage alkyne formation and hydrogenation reactors, and improve the operational efficiency of the plant by modifying Tower T104 and the hydrogenation reactors. Classify and organize the water use and drainage in the branch plants, focus on water usage at the source to prevent indiscriminate use of fresh water. Regularly inspect rainwater wells and sewage wells on site to avoid cross-contamination. Implement quantitative and regular drainage management for various units to prevent uncontrolled discharge. Strengthen oversight of water use and drainage practices, and continue to explore treatment methods such as adding carbon dioxide or sulfuric acid to hydrogenation activation water. Accelerate the separate treatment of deionized wastewater using anion and cation exchange resins to address this long-standing issue. Ensure that acetylene generation processes use fresh water as designed, and work together with the company’s R&D department to carry out improvements to wastewater treatment systems, thereby promoting clean production of BDO. The Phase II acetylenation efficiency improvement project is a key initiative for BDO to further increase its production capacity; it will completely address the issue of insufficient BYD production, extend the service life of the acetylenation catalysts used in Phase II. The branch plant will provide proper coordination during the construction phase, carrying out inspections three times a day and implementing four types of routine checks, in order to complete the commissioning process as soon as possible and thus significantly boost the production capacity of the BDO facility.