Record of the efforts to increase production and reduce costs, as well as to innovate and unlock potential in the compression workshop of Pingyuan Chemical Fertilizer Plant No. 2

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A Record of the Efforts Made by the Compression Workshop of Pingyuan Chemical Fertilizer Plant No. 2 to Increase Production and Reduce Consumption through Innovation and Efficiency Improvements. Author/Source: Pingyuan Chemical. Date: 2022-04-26. Clicks: 17. The Compression Workshop of Pingyuan Chemical Fertilizer Plant No. 2 has thoroughly implemented the requirements related to dual control of energy consumption and energy-saving measures, and by taking into account the actual conditions of the workshop, it has achieved tangible results in increasing production while reducing consumption. By strengthening the foundation and reducing production costs, as temperatures rise each year, the 6M50 compressors and carbon dioxide compressors in the compression workshop require the use of additional circulation oil pumps. To keep the oil pressure within the specified range, it becomes necessary to use two or even three oil pumps instead of just one. Adding an oil pump not only increases the maintenance costs for that pump but also leads to higher electricity consumption, thereby increasing production costs indirectly. To address this issue, the team in the compression workshop conducted thorough investigations and active explorations, examining aspects such as the performance of the oil pump, the heat exchange efficiency of the oil cooler, the layout of the oil pipelines, the pressure difference across the oil filter, and the clearance in the crosshead slideways. Ultimately, it was determined that the reason for needing to add an additional oil pump was the poor performance of the existing oil pump as well as the inadequate heat exchange efficiency of the oil cooler. After identifying the cause, the workshop carried out thorough repairs on the oil pump, and also inspected, maintained, and serviced its bearings, mechanical seals, relief valves, etc., in order to increase the output power of the oil pump. On the other hand, the oil cooler is inspected; by backwashing and checking for any debris in its circulating water channels, the heat exchange efficiency of the oil cooler is improved. Thanks to the implementation of this series of measures, all units of the 6M50 compressors are now operating in single-pump mode. Compressors No. 2, No. 4, and No. 5 for carbon dioxide also operate in single-pump mode; the oil pumps in two more units require maintenance, and it is expected that all of them will be able to operate in single-pump mode once the repairs are completed. Unleash potential by making good use of idle equipment. The poor heat exchange performance of the first and second stage coolers in the carbon dioxide compressor results in high exhaust temperatures at both stages. This poor heat exchange not only reduces the compressor’s pumping capacity and affects urea production, but it also poses negative impacts on the long-term stable operation of the equipment. To resolve this issue, the compression workshop turned its attention to the idle coolers in the monohydric alcohol system of Fertilizer Plant No. 2. By reviewing the drawings, and ensuring that the material of the coolers, their design pressure, and design temperature are suitable, two coolers were selected for installation on the carbon dioxide compressors, thereby making full use of the idle equipment and maximizing the potential of the existing production facilities. The approval for the transfer of the two coolers as fixed assets has been obtained, and they are currently in the process of being disassembled and installed. After installation and commissioning, it can effectively reduce the exhaust temperature in stages 1 and 2, increase the compressor’s air delivery volume, and boost urea production. Comment: Dual control of energy consumption and efforts to save energy and reduce consumption are important measures to minimize resource waste and promote the long-term healthy development of enterprises. The compression workshop of Fertilizer Plant No. 2 has made practical efforts to increase the \"value,\" \"innovation level,\" and \"sustainability factor,\" and has carried out valuable explorations and practices in the area of dual control over energy consumption.