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Shaneng Xinjiang Coal Chemical’s 600,000-ton alcohol-ammonia co-production project has reached full capacity and operational efficiency. Author/Source: Date: 2022-12-07 Clicks: 36. This 600,000-ton alcohol-ammonia co-production project was the first coal chemical project built and put into operation by the former Yankuang Group in Xinjiang. With an investment of over 5 billion yuan and covering an area of 1,050 mu, it utilizes seven internationally advanced and domestically top-tier technologies owned by the group company, including multi-nozzle water-coal slurry pressurized gasification; its designed annual production capacity is 300,000 tons of synthetic ammonia, 520,000 tons of urea, and 300,000 tons of methanol. Since its commissioning at the end of 2012, the project has failed to achieve full operational capacity and efficiency due to various factors such as coal quality, equipment, and personnel; it ranks last in terms of profitability within Yankuang Group. Years of continuous losses have placed the project in a critical situation where its survival is at stake. In 2015, after more than 20 rounds of planning, adjustment, and revision, Yankuang Xinjiang Coal Chemical Company implemented organizational optimization and restructuring as well as competitive recruitment processes, completely breaking away from the old practices of allowing managers to remain in their positions regardless of performance and adhering solely to seniority. Moving away from the approach of pursuing high system loads and operating beyond design specifications, the production operation strategy has been comprehensively revised; by comparing the operation cycles of various key units with those of leading enterprises, the level of management in production operations has been improved. Focusing on the key areas where the gasification system operates unstably, dual oversight was strengthened over coal sourcing and quality standards; a dedicated team was formed to search for suitable coal sources. Over three years, they traveled 300,000 kilometers and conducted comprehensive investigations of more than 30 mining sites in 7 mining areas across Xinjiang. They performed over 230 analyses of viscosity-temperature curves, successfully identified 5 new coal sources, and established two systems for managing both backup and current coal supplies, thereby overcoming the limitations posed by relying on a single coal source. By relying on diversified coal sources, and while ensuring safe production, more than 110 coal mixtures were tested to continuously optimize the coal composition; this improved the gas generation capacity of the gasification furnace and overcame the technical challenges associated with its long-term operation. Pay close attention to key indicators and reverse the state of laxity. Using 13 key production indicators as assessment data, labor innovation competition plans aimed at achieving high output with low consumption and improving quality and efficiency are formulated; output, consumption levels, and wages are linked together to fully motivate the enthusiasm of front-line workers ； All types of accidents that affect system operation, cause unplanned shutdowns, or impact product quality are carefully analyzed, and the relevant responsible units and individuals are subject to strict and severe penalties. This has effectively enhanced employees’ awareness of efficiency and reduced inefficiencies in production management. At the same time, implement technical upgrades and measures to improve operational efficiency. By identifying the bottleneck issues that restrict the operation of the system and its efficiency, a series of innovative measures were implemented, including renovations to the methanol converter collectors, the trays in the urea synthesis tower, the VOCs control systems in the methanol storage tanks, and the automatic weighing equipment for urea packaging. These efforts significantly improved the automation level of the urea packaging, stacking, transportation, and loading processes. The conversion rate of the high-pressure system increased from 59% to around 61%, while the urea production volume rose from the originally planned 1,733 tons per day to a maximum of 2,030 tons per day. As a result, methane emissions into the atmosphere were reduced by approximately 901 tons per year. Leveraging the Engineering Research Center for Water-Coal Slurry Gasification and Coal Chemicals, efforts have been made to establish a platform for the development of scientific and technological projects. Addressing the design flaws and omissions in the early stages of these projects, 17 innovation and efficiency improvement measures were formulated, including those related to ensuring the full operational capacity of the facilities and achieving steam balance. To date, 12 patents have been obtained; among them, the research and application of water-coal slurry gasifiers for Zhundong coal, as well as the high-pressure operation method without venting in urea production facilities, are at the leading level in China. A series of innovative measures have gradually stabilized the company’s production organization, fundamentally improved its operating environment, and completely eliminated the situation of the system running intermittently. Product output increased from 470,000 tons in 2015 to 870,000 tons in 2018 and further to 1 million tons in 2021, with full utilization of production capacity. In 2021, a profit of 360 million yuan was achieved, marking the achievement of optimal production levels and a successful rebirth of the company.