Thread Content
All employees of Fertilizer Division I at Ningxia Petrochemical are working throughout the entire process to promote energy conservation and consumption reduction. Author/Source: Ningxia Petrochemical; Date: March 11, 2022; Page views: 10. Since the beginning of 2022, Fertilizer Division I has focused on energy-saving efforts during the transition from winter to spring. Building upon continuous optimization of plant operations, it promptly formulated relevant energy management measures. These measures primarily aim at eliminating any leaks and spills at the site as well as improving energy efficiency within the production processes, thereby ensuring that energy consumption does not experience any unexpected spikes due to anti-freezing and anti-solidification measures. This approach lays a solid foundation for achieving the annual targets related to energy conservation and consumption reduction. In response to the issue of insufficient production despite full operational capacity that had arisen earlier, the department took reducing unit consumption and increasing liquid ammonia production under similar load conditions as a starting point for addressing this problem. It carefully analyzed changes in the composition of natural gas, and used pressure regulators in the medium-pressure steam network to control the amount of high-pressure steam available, thereby reducing waste from venting ； Adjust the purge gas volume of the synthesis system and the temperature of the gas entering the membrane to increase the high- and low-pressure hydrogen concentrations for hydrogen recovery ； Efforts were concentrated on temperature measurement and leak detection for the flare emission system as well as all vent valves and safety valves. This enabled the timely identification and rectification of an internal leakage issue in PIC1502B, which was causing an increase in flare emissions and hindering the rise in ammonia production. As a result, daily ammonia output increased by approximately 20 tons. Due to the frequent failures of the air pump in the originally designed condensate recovery unit for medium-pressure steam condensate, there is excessive vapor-liquid entrainment in the flash tank V8004 for medium-pressure steam condensate, which prevents the complete recovery and reuse of such condensate. To address this issue, the department has continuously carried out optimizations and renovations of the pipeline network. Through a “repurposing existing equipment” approach, a cooler, a separation tank, and a recovery pump were added after V8004. Additionally, a level indicator was installed in the central control room; this setup enables the pump to automatically start when the liquid level reaches 80% and to shut down when it drops to 20%. After the technical upgrade project is put into operation, all steam condensate will be recovered to the demineralized water unit, thereby achieving energy savings and reduced consumption. Currently, the construction of the project is in its final stage. Once it becomes operational, 10 tons of condensate will be successfully recovered per hour. Additionally, the department has taken measures regarding water and electricity usage; by repurposing existing facilities, it recycles the continuous flow of water required for winter anti-freezing and anti-condensation heating. Temperature monitoring of pump bearing housings helps reduce the opening degree of the circulating cooling water valve under conditions ensuring optimal and safe operation of the pumps, thereby conserving water ； On a monthly basis, technical management personnel organize the team members to conduct thorough inspections of the valves and pipelines on site. Any signs of air leakage are recorded, and repairs are carried out promptly to prevent further damage. Since a continuous flow of water is necessary to prevent freezing and condensation along the waterline, this practice should be included in the shift handover procedures; the water flow should be turned off promptly when temperatures rise, to avoid the occurrence of a true continuous flow of water.