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Keyuan helps boost the intelligence and efficiency of Ningxia’s coal chemical industry! Author/Source: Date: 2022-12-09 Clicks: 22 Against the backdrop of volatile international oil prices, the world has entered an era of diversification in energy and chemical raw materials, and coal resources have become an important source of support for China’s energy supply. Developing coal chemical industry, adjusting China’s energy and chemical industry structure, and adopting advanced control technologies are conducive to improving the automation level of this industry; they hold great significance for promoting its development and achieving the \"dual carbon\" goals. Recently, the Ningxia Baofeng “3 million tons per year coal coking integrated production project” and the Ningxia Runfeng “100,000 tons per year synthetic ammonia DCS+SIS+GDS control system and air separation DCS project”, both based on Keyuan’s self-developed and controllable NT6000 DCS system, were successfully put into operation. Leverage autonomous and controllable advanced control technologies to propel “Ningxia Manufacturing” toward “Ningxia Intelligent Manufacturing”. Ningxia Baofeng: 3 million tons per year coal coking integrated production project. Located in Ningdong Coal Chemical Industry Base, one of the best in China, Ningxia Baofeng has, through over a decade of development, established the largest and most fully integrated high-end coal-based new materials circular economy industrial cluster in the country, covering sectors such as coal, coke, gas, methanol, olefins, polyethylene, polypropylene, fine chemicals, and new energy. The project covers all stages of coal coking, and its main construction elements include a coal storage and distribution system, a coking system (including wet quenching, coke screening, surface dust removal stations, and flue gas desulfurization and denitrification), as well as a gas purification and recovery system. Efficient data collection: This project is an integrated one covering environmental protection, process control, and auxiliary systems. It involves 10 cabinet rooms, 4 control rooms, and over 80 cabinets, with more than 23,000 I/O points. Thanks to the flexible distributed layout scheme and a variety of data acquisition interfaces provided by the Keyence NT6000 DCS control system, the data collection rate for this project exceeds 99%. Multi-system coordinated control: This project takes into account the process requirements of various operations in coking as well as Baofeng’s actual production needs, enabling coordinated operation between the DCS system and the five types of vehicles used in coke ovens. It also allows for the control of dust removal fans on both the machine side and the coke side; the frequency of these fans can be adjusted automatically in real time whenever vehicles such as coal loading cars and coke pushing cars carry out their tasks, and the systems for quenching coke and operating dust removal bins can also be activated automatically in real time. One-key start for coal preparation and coking screening sections: Through one-key control of these sections, functions such as sequential start/stop of belts, safety interlock protection, and indication of the first unit to stop in case of a fault can be implemented. This ensures the safe and stable operation of the equipment, while automated production helps to reduce staff numbers and increase efficiency. Ningxia Runfeng: 100,000 tons per year synthetic ammonia DCS+SIS+GDS control system and air separation DCS project. Located in Ningdong Coal Chemical Industry Base, one of the best in China, Ningxia Runfeng covers an area of 1,000 mu. Runfeng Technology has established itself through its strong capabilities and research and development skills. To facilitate the further development of the company, increase product diversity, and meet market supply demands. In 2021, Runfeng Technology began preparations for a project to produce 100,000 tons of synthetic ammonia per year, and the facility came online in June 2022. The process involved in this project is relatively complex; the raw materials for the product must undergo reactions under specific conditions of pressure, temperature, and catalysts, and then go through a series of subsequent processing steps to yield the final product. Keyuan Smart undertook the design, implementation, and commissioning of DCS, SIS, and GDS systems for sections such as synthesis, air separation, PSA compressors, and tank farms in this project. Automatic control of molecular sieves in the vacuum separation section: In this section, through multiple discussions with the design institute and the owner, the sequential control scheme for the molecular sieves was continuously improved. This enabled functions such as one-click start/stop of the molecular sieves and manual step selection, reducing unnecessary manual operations and ensuring the efficient and safe operation of the plant. Thanks to their professional technical skills, extensive implementation experience, and the \"five ones\" service philosophy, Keyuan’s delivery teams manage to complete project delivery within the specified time frames, while also implementing various functional improvements tailored to the owners’ specific needs. Since operation began, both control systems have been functioning properly, and all product specifications meet the required standards. As a leader in the development of smart industries, focusing on the coal chemical industry, Keyuan has established a comprehensive set of products, solutions, and delivery services. To meet the automation control requirements of coal chemical enterprises, automatic control solutions can be designed based on typical processes such as coal preparation, coking, chemical production, tank farms, dry quenching of coke, utilization of coke oven gas, wastewater treatment, and air separation. Full data collection and data interconnection enable efficient energy management and high-level operational scheduling, ensuring safe production and significantly improving the level of automation. The successful application of this self-controlled NT6000 DCS system in Ningxia’s coal chemical industry fully demonstrates the completeness and advancement of Keyuan’s automation control products and technologies. In the future, Keyuan will continue to develop more innovative and competitive intelligent chemical industry solutions, to assist more coal chemical enterprises in achieving automation and intelligent transformation.