Zhongtai New Materials’ Gasifier No. 3 achieved successful commissioning on the first attempt

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Recently, data from the production site of Zhongtai New Materials showed that Gasifier No. 3 was successfully started up in a single attempt. This ignition is not merely the activation of the device; it represents a revolution in the traditional logic behind starting up coal-based chemical processes. As the \"heart\" of coal chemical plants, starting up the gasifier has always been a high-stakes task. If there is a deviation in the pressure equalization process, it may result in fluctuations in system pressure at best, or even a shutdown of the entire production line at worst. Previously, the industry generally adopted a \"step-by-step relay\" approach: first, the syngas was fed into the purification system for buffering, and then introduced to the synthesis system in stages. Although this process is reliable, it takes over 10 hours in total, with a lot of unnecessary waiting time. Faced with the challenge of the concurrent occurrence of the project completion phase, the trial production adjustment period, and the production operation transition phase, Cao Xiangmin, the deputy general manager of Zhongtai New Materials, provided a solution: eliminate redundant processes and achieve efficiency through precise management. The core strategy put forward by the technical team this time is one called \"dual-system synchronous pre-tuning and direct connection of pressure gradients\". They broke away from the notion that a purification system was necessary as an intermediate step; by continuously monitoring the three key parameters of pressure, temperature, and composition in both the gasification furnace and the synthesis system, they achieved precise dynamic coupling control, thus creating a direct \"high-speed pathway\" from the gasification furnace to the synthesis system. This refined set of operating procedures completely transformed the operator’s experience. Gao Zhiping, the director of the gasification workshop, revealed that in the past, step-by-step operations required constant monitoring of two separate systems for adjustments, as there were concerns regarding parameter fluctuations as well as the risk of excessive time consumption. With the implementation of the new solution, intermediate transition steps are eliminated, and the compliance rate of syngas quality reaches 100%, truly achieving \"faster processing without a decline in quality\"; operations at the front line become both simpler and more efficient. The startup time was reduced by a full 2 hours and 54 minutes, going from over 10 hours to just 7 hours and 6 minutes – a figure that sets a new record for the shortest time taken since the company began trial production. This case demonstrates that refined management is not just a slogan on the wall, but rather scientific control applied to every pressure gauge and every temperature monitoring point. Currently, the key technical experts at Zhongtai New Materials are focusing on overcoming the final challenges related to the dynamic regulation of pressure at the outlet of the gasification furnace and the coordinated optimization of the purification system, thereby pushing production management in the direction of greater intelligence, efficiency, and safety. The total investment in this project is 5.991 billion yuan. It utilizes advanced domestic coal chemical technology to produce methanol from waste gas, as well as coal powder and coke dregs as raw materials, featuring low energy consumption and low emissions.