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Pu Jie Energy & Chemical Heat Power Center: Achieving \"Cost Reduction and Efficiency Improvement\" Author/Source: Pu Jie Energy & Chemical Date: 2022-03-18 Clicks: 1 Pu Jie Energy & Chemical’s production and operations are making steady progress toward achieving excellent results in the first quarter. Among these, as the thermal hub of the entire plant’s power system, it uses wisdom and experience to explore new paths for reducing costs and increasing efficiency. Coal is a raw material for chemical production and the foundation of clean energy. As the \"granary\" of the plant’s production system, the original transportation equipment in the thermal power center plays an irreplaceable role. How can we ensure a sufficient supply of coal for the entire plant’s production, while keeping the annual coal consumption within the budget, and thus achieve a win-win situation of \"efficient combustion and cost reduction\"? This is the challenge that the center’s \"original carrier\" has long been committed to solving, as well as the goal it strives to achieve. Through research and analysis, it was found that the fine slag resulting from combustion in the gasifier contains a high carbon content. To avoid waste of resources, the technical staff in charge of transportation conducted thorough and precise calculations as well as detailed analyses, and taking into account the company’s relevant requirements, decided to adopt the new approach of \"refining coal from fine slag\" in order to reduce coal consumption. In other words, the fine slag with a high carbon content generated by combustion in the gasification furnace is made full use of; through processes such as dehydration and drying, it is filtered and purified to meet the standards for coal used in the boilers at this facility. Subsequently, it is effectively utilized by taking into account comprehensive factors such as its calorific value and the degree of coking in the furnace. “In the process of determining the proportion of coal used for boiler combustion, precision is of utmost importance in order to achieve the best results; otherwise, it can lead to issues such as a decrease in the calorific value of the combustion and fluctuations in load. ”As explained by Zhang Xichao, the technician in the original logistics position. Today, through repeated precise training and diligent practice, the operator for this position is now highly skilled at adjusting the coal blending ratios with confidence. The successful implementation of this \"solution\" not only effectively promoted the secondary use of energy but also **reduced production and operating costs**. According to statistics, the original transportation device can reduce coal consumption by about 100 tons per day, saving over 30,000 tons of coal throughout the year, thus taking the first step toward reducing costs and increasing efficiency right from the source. “When feeding coal into the original coal transportation system, a staggered production approach was employed, which reduced the duration of operation during peak electricity prices and thus lowered power consumption ； Utilize waste materials to make common tools such as soot blower handles, furnace coking rods, and simple oil containers, thereby saving some expenses ； Ensure that the cleaning of excess coal is carried out properly, so that not a single drop of resources is lost ； Valve leaks in the heat pipeline drainage system are tightened up immediately to prevent the leakage from worsening, which could lead to attempts to seal it under pressure and result in unnecessary costs… In the warm months of March, the heat management center comes up with numerous innovative ideas and effective practices aimed at reducing costs and increasing efficiency. The entire staff at the center has taken advantage of the “Strive for Excellence and Be Energy-Saving Guardians” campaign initiated by the party branch to continuously uphold the company’s culture of paying attention to details. From energy-saving practices in daily life to measures to reduce consumption in production, efforts are made to measure individual contributions and team efficiency, with scores being used to track performance, thus sparking a widespread initiative aimed at reducing costs and increasing efficiency through everyone’s participation. To further implement the list of measures aimed at reducing costs and increasing efficiency and to achieve tangible results, the center adopts a precise management approach that focuses on daily tasks for weeks, weekly tasks for months, and monthly tasks for years – with responsibilities assigned to specific teams and individuals. Tasks are broken down in detail, and standards are applied at each job position, so that everyone feels the pressure and takes responsibility. At the same time, the operation team insists on calculating various production unit costs on a daily basis, conducts in-depth analysis of operational costs, submits research results on time, and strengthens cost control comprehensively, thereby creating a stable situation where costs are under control within a closed-loop management system. At the beginning of March, with the official commissioning of the new low-flow feed water pump P110 at this facility to replace the high-power hydraulic coupling motorized pump, 1,500 kWh of electricity can be saved per hour, which amounts to 36,000 kWh per day. At an average cost of 0.5 yuan per kWh, this results in savings of 18,000 yuan per day, further improving the results achieved under the special initiative aimed at reducing costs and increasing efficiency.