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Rongxin Chemical’s independent innovation in optimizing work processes in its purification workshop / Author/Source: Rongxin Chemical / Date: 2022-02-13 / Clicks: 17 Since Rongxin Chemical began to implement the integration of industrialization and informatization on a systematic basis, its purification workshop has emphasized practical action, with all employees working to improve processes through independent initiatives and suggestions, thereby achieving better quality and efficiency, reducing labor intensity, and cutting down costs. Independent process improvements were made. Before these improvements, the adjustment of the hydrogen-to-carbon ratio in the second-stage system was slow, preventing it from being adjusted to the normal range in a timely manner, which resulted in large fluctuations in system pressure. Operating the transformation control room is difficult, resulting in a passive situation. To track the appropriate CO level as quickly as possible, the personnel in charge of making adjustments have proposed many feasible solutions. The composition of CO is adjusted by using a low wash outlet pressure; controlling this low wash outlet pressure allows for real-time regulation of the CO at the conversion outlet, which effectively reduces the operational difficulties and passive situations faced by the personnel responsible for the conversion process. Fine tuning of the CO level at the converter outlet can also be achieved by adjusting the water vapor ratio; increasing the water vapor ratio means more steam is available to participate in the conversion reaction, which results in a decrease in the CO level at the converter outlet. By reducing the water vapor ratio, less water vapor is available to participate in the shift reaction, resulting in an increase in CO levels at the outlet of the shift reactor. This allows for early prevention, helping to balance the trend of low outlet pressure. After the implementation of these effective solutions, it reduces the difficulty of operations for the operators involved in transformation processes as well as their reliance on external factors, thereby preventing excessive fluctuations in system pressure from affecting methanol production. Independent improvements were made on the equipment. Since the operation of the first-phase propylene compressor system began, the oil fumes from the oil stations were discharged directly outdoors on the west side of the site, leading to the accumulation of such fumes and the contamination of surrounding walls, floors, and pipelines. Considering the issues related to clean and orderly site management, Jin Xin, the deputy team leader of Team C, proactively proposed corrective measures. He used the unused equipment from the second-phase torch material storage area to convert it into a simple buffer tank, which was placed near the original discharge point; the height of the tank was increased to facilitate oil discharge in later stages. After the cooking fumes are introduced into the tank for buffering and separation, the smoke is led to a high point at the top of the tank for release, while the solidified oil accumulates at the bottom and is discharged periodically for collection and treatment. By modifying the system to separate the cooking fumes, these fumes no longer pollute the surrounding environment, and oil stains no longer appear on the floors or pipes. After the renovation of the fume buffering and separation system, there is no oil contamination, eliminating the environmental pollution caused by the direct discharge of fumes and achieving the goal of clean production. In the second-phase transformation project, the actuator of the manual valve at the inlet of Transformer No. 2 is in an inconvenient position, making operation difficult. The original design of the valve’s handwheel faced downward; therefore, when it was necessary to open or close the valve, operators had to sit on the cold ground in order to reach the actuator. This inconvenient positioning made it difficult to apply sufficient force to operate the valve, thereby significantly reducing the efficiency of the system. It cannot meet the operational requirements of on-site personnel. Following the autonomous improvement by operator Yunjeong through transformation steps, the direction of the actuator was changed, from the valve knob facing the ground to the knob facing west. By now changing the orientation, this actuator **saves labor and improves switching efficiency. To improve safety on its own, since the commissioning of the Low-Temperature Methanol Wash II system, it was found that the remote control valves for directing hydrogen-rich gas from the outlet of the shift gas feed cooler to the methanol synthesis unit, those for directing methanol synthesis gas from the inlet of the shift gas feed cooler to the hydrogen-rich gas stream, and the remote control valve for directing CO from the outlet of the unshifted gas feed cooler to the methanol synthesis unit were not properly sealed, resulting in leaks. These valves could not provide effective isolation during normal operation of the system. In order to ensure that the raw gas entering the PSA and deep cryogenic separation units met the required standards, it was not possible to extract CO2 from the shift gas methanol wash tower; instead, the unshifted gas methanol wash tower used manual valves at the outlet of the unshifted gas feed cooler to regulate the pressure difference between the two sides of the heat exchanger. In response, Zhi Wenhao, the workshop process engineer, proposed corrective measures to install manual gate valves in front of these two large valves in order to ensure effective isolation of the syngas. It serves to cut off the process gas flowing into the second-stage low-washing system, ensuring safety for personnel and the local ecological environment in emergency situations where there is an increase in leakage at the seal surfaces of the remote control valve that directs the hydrogen-rich gas from the converter gas feed cooler outlet to the methanol synthesis unit, as well as the remote control valve that directs the methanol synthesis gas from the converter gas feed cooler inlet to the hydrogen-rich gas stream. Self-improvement is one of the important ways to enhance employees’ overall competence, improve their operational skills, and ensure safety and efficiency. Small improvements **contributed to the enhancement of lean practices. It is reported that within the first month of its operation, the purification workshop implemented 14 autonomous improvement initiatives for various positions. Through everyone’s efforts and hands-on improvements, while striving to excel in their respective roles, they contributed to enhancing the quality and efficiency of the company.