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Pu Jieneng Chemical: A \"hot\" production line delivers \"shining\" results Author/Source: Shaanxi Coal Group Date: 2022-07-03 Clicks: 11 In January, 74,700 tons of polyolefin products were produced, setting a new record for the highest monthly output and marking a successful start to the year”； In February, the average daily output of polyolefins reached 2,384 tons, hitting a record high ； In the first quarter, the production of polyolefin products reached 214,000 tons, marking a strong start to the year and bringing vitality to the springtime in Weibei ； In April and May, profitability was achieved for the first time during the annual maintenance period ； In the first half of the year, the output of polyolefin products reached 410,000 tons, exceeding the planned target for the period by 111% and setting a new record... As the primary responsible unit for safe production, the Production, Maintenance and Operations Center took proactive measures and diligently fulfilled its duties. In the production system, each center conducted self-inspections and rectifications regarding the implementation status of interlock and automatic control systems. The interlock implementation rate increased by 1.75% compared to the whole of 2021, while the automatic control implementation rate rose by 11%. As a result, the safety performance of the process equipment has been significantly improved ； The Production Technology Department has established a safety management system for process operations. It regularly conducts HAZOP analyses to identify weaknesses and loopholes in process management, ensuring that safety is integrated into every stage of the process and implemented in every detail. In the first half of the year, the department’s \"Management Methods for Outsourced Contractors\" were revised, with safety management included as an important indicator for quantitative assessment, **which improved the safety awareness and management standards of the outsourced workforce. In the logistics system, a safety management mechanism operating on a \"dual-track\" basis, both internally and externally, is gradually taking shape. On the basis of organizing weekly inspections of equipment in areas with major hazards and carrying out special \"accident-prevention\" campaigns among the three specialties related to mechanical, electrical, and instrumentation systems, the Mechanical, Electrical, and Instrumentation Technology Department extends the framework of safety management. It imposes stricter requirements on the safety management of outsourced teams, ensuring that these teams are integrated into the company’s safety management system, work together as one unit, and form a cohesive force. Turning the clock back to the beginning of the year, under the wave of discussions centered on “optimization and improvement”, Pujie Energy & Chemical Company pooled collective wisdom to address both major issues and minor hassles that affect stable and high-level production. After intense discussions, over 300 optimization measures were implemented from and to the production line, laying a solid foundation for stable and high-level production. Notably, the Production Technology Department has taken measures such as establishing a safety management system for process operations, setting up a daily analysis and corrective mechanism for output, and formulating procedures for handling fluctuations in production load. These efforts have effectively put into practice the principle of ensuring stable output on a “daily basis to guarantee monthly results, monthly efforts to ensure quarterly outcomes, and quarterly actions to secure annual targets.” ； The “equipment defect management” system implemented by the Mechanical, Electrical, and Instrumentation Technology Department ensures that deep-seated equipment defects cannot go unnoticed, resulting in the longest operating time records ever achieved for the extruders in polyethylene and polypropylene plants. Time quickly moved on to April and May on the Weibei Plain – the maintenance months for Pujie Energy & Chemical Company. In chemical enterprises, annual maintenance is an effective measure to ensure the safe and stable operation of the facilities. However, shutting down for maintenance will inevitably affect production. What should be done? After extensive research and deliberation, Pujie Energy & Chemical Company innovatively introduced the “maintenance while operating” model. This involves scheduling shutdowns and maintenance for various units and systems in a staggered manner, thereby fully maximizing their production capacity and paving the way for stable and high-level output. From April to May, Pujie Energy & Chemical Company successfully completed its maintenance work, which took nearly two months. The company produced 130,500 tons of polyolefin products. This figure represents a mere 5.4% decrease compared to the normal production volume during the same period in 2021. The company earned a profit of 90 million yuan, achieving a full-year profit for the first time following its annual maintenance. Adhere to the principle that \"reducing consumption means reducing costs\" throughout the entire production process. The methanol production facility focused on process optimization for coal slurry concentration improvement, successfully raising the slurry concentration from 62.5% to over 63.5%, which resulted in an increase of 80 tons per day in methanol output ； The Olefins Center focused on tackling the bottleneck that hinders the long-term, high-load operation of MTO units. This effort not only resolved the problem of low yields of ethylene and propylene, but also reduced the specific consumption of olefins to 2.9294 tons per ton of product, reaching a leading level in the industry ； The thermal center upgraded the boiler burners, reducing the residual carbon in fly ash to below 5%; the average fuel coal consumption per ton of steam in the first half of the year was 7.77% lower than that in 2021 ； The Water Treatment Center implemented optimization measures for the recirculated water and reused water systems, resulting in a 22.00% reduction in the water consumption per ton of polyolefins produced ； The Production Technology Department actively analyzes the nitrogen usage patterns across the entire plant, and allocates nitrogen resources to various users in a scientific manner; as a result, the average daily nitrogen consumption is 30,000 standard cubic meters less than last year ； The Assurance and Operation System has vigorously promoted initiatives such as the domestic substitution of spare parts and the reuse of repaired items, resulting in cost savings of over 2 million yuan... Cost-reduction efforts are proceeding apace, while efficiency-enhancement measures are also being implemented across the board. The sales center actively analyzes the market, striving not only to sell its products but also to achieve good prices and earn a solid reputation. In the first half of the year, the center worked on strengthening its internal capabilities by restructuring and reorganizing its existing sales teams to foster healthy competition. This motivated all staff members to “get moving” in pursuit of success; as a result, 15 new clients were acquired. Meanwhile, efforts were made to boost efficiency through the implementation of a “production based on sales” mechanism, leading to the cumulative sale of polyolefin products under 8 different brands ； Advance the trading of chemical bulk commodities through online platforms; 102,600 tons of polyolefin products were successfully traded ； By proactively serving customers and offering road delivery services for polyolefin products, the company gained more loyal clients… In the first half of the year, Pu Jieneng Chemical Company met its half-year sales target one month ahead of schedule, setting a new record for sales. The Procurement and Supply Center deepened the “replace old with new” management mechanism, revitalized accumulated inventory, and generated economic benefits of 700,000 yuan. In addition to implementing the aforementioned measures, various technological innovation projects aimed at expanding avenues for corporate efficiency gains—such as the comprehensive utilization of hydrogen energy, the comprehensive utilization of C4, and differential pressure power generation—are being advanced in full swing. These efforts will provide Pujie Energy Chemical with the wings it needs to achieve high-quality development. Puji Energy Chemical Company will always maintain a mindset of “taking an exam”, persevere in its efforts, and continue to strive on the path of achieving excellence and high-quality development for the enterprise, so as to produce even better “results”.