How do you handle defects in the synthesis process?

For leaks in the synthesis unit, it depends on what type of leak it is; if it’s a low-pressure system, try to recover the ammonia (consider using clamps on the ammonia gas pipelines). Just replace it with water after verification, and then carry out the treatment; if it’s steam and the amount isn’t too large, keep production running first and handle it when there’s an opportunity to shut down the system. In the case of a high-pressure system, an emergency shutdown is required; an emergency shutdown is also necessary in the event of a fire. Pressure must be released in accordance with the procedures, and areas where welding is to be carried out must first be made suitable before any work can proceed. If it’s a water system, a stopcock can be used, and parking space is available for handling it. If the leakage is severe, an emergency shutdown is carried out first.

If there is a leak in the high-pressure section, it is generally sufficient to reduce the system pressure slightly and then tighten the components while the pressure is still present. If the treatment under pressure is not done properly, the system must be shut down for handling. Leaks occur in the low-pressure section; it is generally difficult to fix them without shutting down the system, and they can only be addressed by stopping the operation.

There is a leak in the high-pressure section; it can only be tightened while under pressure. If that doesn’t work, it will have to be dealt with after the system is shut down.

There is a leak in the high-pressure section; the system pressure needs to be reduced below 5.0 MPa in order to tighten the components under pressure. If the treatment under pressure is not done properly, the system must be shut down for handling.

For initial leakage of the valve packing, the gland can be tightened evenly； Especially when the pressure behind the valve is not high, closing the valve and tightening the packing generally yields satisfactory results. For leaks in pipe flanges and vessel flanges, the only options are to shut down the system by releasing pressure or to reduce the pressure to below 10 MPa (for systems at 32 MPa) before tightening; operating at higher pressures is purely risky ； If tightening does not work, it may be a problem with the gasket or the sealing surface. If a weld in a high-pressure pipeline leaks, the situation can develop very rapidly; the pipeline usually breaks within no more than a minute. In such cases, the entire system must be shut down immediately, pressure must be released quickly, the leak location must be isolated as much as possible, and measures to prevent fires and explosions as well as firefighting preparations must be put in place.

Handle what can be dealt with; for those that cannot be handled, use pressure-sealing methods to stop the leak. If it affects normal production, then shut down the system to address the issue

Last year, a leak occurred at the root valve of the flow measurement point for the syngas compressor outlet. We started preparing to seal the leak using clamps, but the system pressure was too high to do so. The only option is to shut down the synthesis system, release the pressure, and then deal with it.

Not long ago, there was a leakage at the top flange of the ammonia produced by our plant. Initially, attempts were made to seal the leak, but due to the high pressure in the synthesis process, these efforts were not very effective; ultimately, the plant had to be shut down for repairs

If there is a leakage at the high-pressure section (lens pad), it is generally sufficient to reduce the system pressure and tighten the components while the pressure is still present. If the treatment under pressure is not done properly, the machine must be stopped for repairs, involving grinding the sealing surfaces and machining the lens gaskets.

Low-pressure leaks can generally be resolved if detected early and dealt with promptly; high-pressure leaks are usually more difficult to eliminate completely, and the best approach is to shut down the system

1. In the initial stage, use the pressure-based leak sealing method, with 8–10 glue injection holes; ammonia-based glue should be used； 2. If leakage occurs again after plugging under pressure, the system must be shut down ； 3. Pay attention to temperature rise during system startup and shutdown ；

Leaks in synthetic processing units are indeed difficult to handle; the main challenges are high pressure and the flammability and explosiveness of the gases. In such situations, attempts are made to seal the leak under pressure, but this sometimes doesn’t work. The system is shut down for minor repairs in order to relieve pressure, after which the components are tightened. If the leak has persisted for a long time, it may cause grooves to form on the sealing surfaces, requiring the components to be removed and the surfaces to be polished.

If there is a leak in the high-pressure section, it is generally necessary to appropriately reduce the system pressure in order to prepare for shutdown. Leakages are occurring in the low-pressure section; if addressed promptly, they should be able to be fixed. If that’s not possible, the machine will have to be stopped