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Huajin Group’s Jintianhua plant has achieved 630 days of continuous operation, becoming a leader in the industry! Author/Source: Zhongbing Huajin Date: 2022-05-31 Clicks: 31 As of May 30, Jintianhua’s ammonia synthesis plant had achieved 630 days of consecutive operation at Class A status across different years, breaking the previous record of 629 days set in 2021 by the ammonia synthesis plant at CNOOC Hainan Fudao Fertilizer Plant. This achievement marked a new milestone in the history of China’s chemical industry regarding the continuous operation of fertilizer production plants. Jintianhua’s synthetic ammonia plant with an annual production capacity of 300,000 tons was put into operation in 1992. It utilizes the cryogenic purification technology developed by Brown Company in the United States. The entire plant had a high level of automation at that time, reaching international advanced standards, and it has been in operation for 30 years now. In 2014 and 2018, it achieved the milestone of operating at Class A status for 300 consecutive days on two occasions; since starting up again after the annual overhaul in September 2020, the unit has now operated at Class A status for 630 consecutive days. Over the past two years, Jintianhua has overcome various external challenges such as the pandemic. On one hand, it has strengthened communication with CNOOC to make every effort to ensure a stable supply of natural gas raw materials ； On the other hand, active efforts are made to establish contact with the relevant departments and suppliers in Huludao City, in order to address major issues that affect the operation of the enterprise, such as power shortages in the grid, supply problems for production materials, and difficulties in transporting urea, thereby ensuring the continuous and stable operation of the facilities. In response to internal challenges such as severe equipment aging and frequent safety hazards resulting from the devices operating beyond their intended lifespan, Jintianhua’s entire organization worked together to address these issues. By focusing on on-site management, and building on the thorough implementation of the “five key systems” for chemical production, the company emphasized equipment management as a means to improve safety conditions. It carried out regular inspections to identify potential hazards, combining self-inspections with specialized checks. Additionally, it adopted incentive mechanisms such as rewards for individual contributions, encouraging employees to conduct thorough inspections. As a result, major hazards such as leaks in the control valves for AC102 synthesis and in the low-pressure end seals of the high-pressure boiler feed pumps were detected in a timely manner, which helped prevent several shutdown incidents. Jintianhua has taken multiple measures to strengthen training. In addition to enhancing systematic training on job-related knowledge and skills, it also conducts “cross-disciplinary” and “cross-departmental” training to foster operators who can handle multiple tasks within one position ； In light of seasonal conditions, severe weather, and abnormalities that occur during the operation of the equipment, emergency plans should be formulated in a timely manner. Additionally, training on these plans and emergency drills should be enhanced to improve the emergency response capabilities of the operators. Striving for innovative upgrades to restore new efficiency to old equipment is another key strategy for Jintianhua to ensure the continuous operation of its facilities. Over the past few years, various bottleneck issues that affected long-term stable operation have been addressed, including the safety upgrades to the compressor unit control system, thereby maximizing the operational efficiency of the facility. During the 630-day operation period, a total of 605,600 tons of synthetic ammonia were produced, bringing significant economic benefits as well as positive social benefits to the enterprise.