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Methanol startup procedure

2009-03-06View Original

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1. Preparations before starting the machine: 1.1 All equipment, pipelines, valves, and instruments have been installed; individual tests, purging, joint tests, and instrument calibration have all been completed successfully. Catalysts, desulfurizers, fillers, and adsorbents have been installed and purged properly. The mechanical, electrical, and control systems are in good standby condition, and all valves are in their correct positions. 1.2 The chemical raw materials, reagents, and materials required for production are all available. 1.3 Ensure smooth traffic flow, and implement all safety, fire protection, health, and emergency rescue measures. 1.4 Parameters and quantities such as water, electricity, and coke oven gas meet the requirements for commissioning. 2. Utility startup procedure: 2.1 Block diagram of the utility startup procedure 2.2 Commissioning of the electrical system – Commission the transformers at various levels to ensure power supply for lighting and communications. 2.3 Commissioning of water intake station and primary water station: 1) Start the water intake pump to supply water to the primary water station. 2) Once a normal water level is established in the primary tank, the high-pressure fire pump is started. When the high-pressure fire water network meets the requirements for high-pressure firefighting, the high-pressure fire pump is turned off, and then the high-pressure fire pressure stabilizing pump is started; the high-pressure fire water system remains in standby mode. 3) Start the production water pump to supply water to the production/low-pressure fire protection water network. 2.4 Commissioning of the circulating water station 1) Open the make-up water valve of the circulating water station to establish the liquid level in the circulating water tank. 2) Start the circulating water pump to supply water to various cooling devices. The inlet/outlet valves of all water-using equipment are fully open to maximize the circulation capacity of water. 3) Start the cooling tower fans; the circulating water station is operating normally. 2.5 Commissioning of the instrument air station 1) The circulating cooling water is in normal condition through the cooling equipment. 2) Start the air compressor and drying system as required to put the instrument air station into normal operation, maintaining the pressure in the instrument air buffer tank at ~0.8 MPa(G), so that qualified instrument air can be supplied to the production units at any time. 2.6 Commissioning of the desalinated water station 1) Open the inlet valve of the raw water tank in the desalinated water station to establish a normal liquid level in the tank. 2) Bring the pretreatment system, reverse osmosis system, decarburization system, and mixed-bed into operation in sequence according to the process flow of the desalinated water station, so as to enable the desalinated water station to operate normally. 3) Once a normal liquid level is established in the desalination water tank and sampling analysis shows that all parameters of the desalinated water are within acceptable limits, the desalination water pump can be started to supply water to the desalination water network. 4) The specific operations shall be in accordance with the operation manual provided by the demineralized water manufacturer. 2.7 Commissioning of the boiler room 1) Start up the air compressor station system in the boiler room to bring it into normal operation. 2) Prepare and supply coal to maintain a normal level in the coal storage bin. 3) Once all dosing systems are ready, liquid chemicals can be supplied to the boiler system normally. 4) Establish a normal liquid level in the deaeration tank, and start the boiler feed water pump to supply water to the boiler. 5) Boiler system boiler cleaning. 6) Gradually bring the boiler back into normal operation. Analyze the steam quality parameters; once they meet the requirements, steam can be sent to the steam distribution networks, thereby establishing the pressure in each of these networks. 7) The specific operations shall be in accordance with the operation manual provided by the boiler manufacturer. 2.8 Commissioning of the air separation system: Operate it in accordance with the operation manual provided by the supplier; oxygen and nitrogen pressures must meet the required levels, and the composition of oxygen and nitrogen as determined through sampling and analysis must be satisfactory before oxygen and nitrogen can be supplied to external pipelines. 2.9 Commissioning of the steam generation station: 1) All dosing systems are ready, allowing for the normal supply of chemical solutions to each waste heat boiler system. 2) Establish a normal liquid level in the deaeration tank, and open the steam valve to put the deaeration tank into normal operation. 3) Sample and analyze the deaerator boiler feed water; once the requirements are met, the boiler feed pump can be started to supply water to the boiler’s water distribution network. 3. Startup procedure for the methanol plant: The startup of the methanol plant must be carried out once the utility systems are fully operational and capable of meeting the requirements for its operation. The commissioning of the methanol plant is carried out following this procedure: System nitrogen purging → Introduction of coke oven gas and establishment of the gas holder level → Startup of the Roots blower; operation of the pretreatment and rough desulfurization systems → Establishment of coke oven gas pressure in the fuel gas network → Startup of the two coke oven gas compressors; establishment of a nitrogen circulation in the conversion system → Filling of the distillation system with deionized water, startup of the distillation air coolers and various reflux pumps, and establishment of a pseudo-material circulation in the distillation system → Introduction of 0.8 MPa steam to establish pressure in the steam network → Operation of the steam generation station → Ignition of the combined heater; heating of the conversion furnace with nitrogen → Heating of the conversion furnace with steam, followed by discontinuation of the nitrogen circulation for heating. Thereafter, the medium used in the coke oven gas compressors is changed to coke oven gas; ignition of the coke oven gas heater; activation of the fine desulfurization system for coke oven gas; switching of the fuel coke oven gas to compressed coke oven gas → Introduction of coke oven gas that has been properly desulfurized into the conversion system, with oxygen being gradually added according to the heating requirements → Operation of the conversion system; discharge of the conversion gas to the flare → Disconnection of external steam from the steam network, and establishment of normal pressure using the by-product steam → Startup of the combined compressor; establishment of a nitrogen circulation in the synthesis system → Operation of the methanol synthesis cooler → Startup of the start-up injector; heating of the synthesis tower with nitrogen → Introduction of conversion gas; catalytic reduction in the synthesis process → Use of the combined compressor to process the conversion gas; operation of the synthesis system; inclusion of the methanol off-gas in the fuel gas network → Establishment of the liquid level in the crude methanol storage tank → Introduction of crude methanol into the distillation system; operation of the distillation system → Operation of the crude methanol metering tank → Delivery of qualified crude methanol to the methanol storage facility, while unqualified crude methanol is returned to the crude methanol storage tank → Operation of the methanol storage facility.

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