Fertilizer plant environmental impact assessment report

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I. Purpose of the assessment: The assessment of the rational use of energy and water in construction projects is conducted in accordance with relevant laws, regulations, standards, and requirements. It takes into account the specific circumstances of each project, evaluating the use of new energy-saving processes, technologies, equipment, and materials, as well as the recovery and utilization of waste heat, waste pressure, and combustible gases, as well as the comprehensive use of resources. This assessment aims to determine the technical feasibility and economic Rationality of energy- and water-saving measures, thereby avoiding unnecessary investments and redundant construction at a low level, and ensuring energy and resource conservation from the outset. II. Bases for Evaluation
1. Relevant laws, regulations, and rules
(1) Energy Conservation Law of the People’s Republic of China
(2) Law of the People’s Republic of China on Promoting Clean Production
(3) Measures for the Management of Energy Conservation
(4) Regulations on Energy Conservation in Shandong Province
(5) Measures for Energy Conservation Supervision in Shandong Province
(6) Interim Measures for the Evaluation and Review of Rational Energy Use in Fixed Asset Investment Projects in Dezhou City

2. Guiding documents
(1) Comprehensive Work Plan of the State Council on Energy Conservation and Emission Reduction
(2) Decision of the State Council on Strengthening Energy Conservation Work, State Council Document No. 28
(3) Notice of the State Council on Issuing Interim Provisions to Promote Industrial Structure Adjustment
(4) Notice of the General Office of the State Council on Carrying Out Activities for Resource Conservation
(5) Regulations by the National Development and Reform Commission, the Ministry of Economy and Trade, and the Ministry of Construction on the Preparation and Evaluation of the “Energy Conservation Section (Chapter)” in Feasibility Study Reports for Fixed Asset Investment Projects
(6) Notice by the National Development and Reform Commission on Strengthening Energy Conservation Evaluation and Review for Fixed Asset Investment Projects
(7) Notice by the General Office of the People’s Government of Shandong Province on Thoroughly Conducting Energy Conservation Evaluation and Review for Fixed Asset Investment Projects
(8) Guiding Opinions on the Comprehensive Utilization of Resources during the 11th Five-Year Plan Period issued by the National Development and Reform Commission

3. National and industry standards and specifications
(1) Outline of China’s Energy Conservation Technology Policies (2006)
(2) General Rules for Calculating Comprehensive Energy Consumption, GB/T 2589-1990
(3) Medium- and Long-Term Special Plan for Energy Conservation, issued by the National Development and Reform Commission in 2004
(4) Guidelines for Evaluating Rational Electricity Use in Enterprises, GB/T 3485-1998
(5) Calculation and Evaluation of the Economic Benefits of Power Saving Measures, GB/T 13471-1992
(6) Guidance Catalogue for Industrial Structure Adjustment (2005 version)
(7) Catalogue of Industries Where Low-Level Repetitive Construction Should Be Prevented at Present

III. Scope of Evaluation
The energy system optimization project for the 30×10^4 t/a urea production facility of Shandong ** Zhongnong Runtian Chemical Co., Ltd. IV. Overview of the construction unit: Shandong **Zhongnong Runtian Chemical Co., Ltd. is a joint-stock company established in October 2002 by the China Agricultural Means of Production Group Corporation in partnership with 21 other shareholders; it is a limited liability company. The predecessor of the company, Shandong **Fertilizer Factory, was established in 1970. Through years of technological upgrades and renovations, it now has a production capacity of 180 kt/a of synthetic ammonia and 300 kt/a of urea. The company currently has total assets of 191.57 million yuan, of which the net assets amount to 96.77 million yuan. There are 2,038 employees, of whom 296 are engineering and technical personnel. With a floor area of 230,000 m2, the company holds an “AAA+” rating in terms of bank creditworthiness. In 2006, the company achieved annual sales revenue of 520.52 million yuan, and generated profits and taxes amounting to 15.71 million yuan, of which the net profit was 6.78 million yuan. The company is currently ranked among the top 50 in terms of urea production within the national small nitrogen fertilizer industry, as well as among the top 50 in terms of sales revenue from synthetic ammonia and its products. It is also part of the top 100 fertilizer companies in China, the top 500 chemical enterprises in China, and the top 500 chemical enterprises in terms of economic efficiency. In 2006, it obtained the **ISO9001-2000 quality management system certification, the license for liquid ammonia production, and the **product quality exemption from inspection certification. Its flagship product, urea, has won honors such as the \"Gold Award at the First China Golden List Technology and Expo\" and the \"Award for the Agricultural Input Product Favorite by Shandong Province Farmers\". Over the years, Shandong **Zhongnong Runtian Chemical Co., Ltd. has, while continuing to focus on the production and operation of traditional urea products, made significant efforts in technological upgrades, innovation, the application of high-tech solutions, and the development of new products, constantly working on creating high-value-added high-tech projects. The peptide urea developed and produced by enterprises overcomes the shortcomings of traditional fertilizers, offering advantages such as environmental friendliness, sustainability, broad-spectrum efficacy, and high efficiency. The metal proteins contained in peptide urea have a strong catalytic effect on the nutrients required by plants; they accelerate the uptake of nitrogen, phosphorus, potassium, and trace nutrients from the soil by plants, thereby reducing the loss of fertilizer nutrients. It is suitable for various plants and soils, and it can improve soil quality as well as the quality of crops. According to tests conducted by the Academy of Agricultural Sciences, compared with the use of ordinary urea in equal amounts, peptide urea can increase crop yields by 15%–20%. Currently, the company produces 130,000 tons of peptide urea per year. This year, Shandong **Zhongnong Runtian Chemical Co., Ltd. signed an agreement with the Chinese Academy of Agricultural Sciences to establish a new fertilizer research and development center. This center will focus on research aimed at enhancing the effectiveness of fertilizers, improving their utilization rate, and raising the quality of agricultural products. The company has successively received numerous honors, including “Clean and Civilized Factory,” “National Advanced Enterprise in Fertilizer Production,” provincial-level “Advanced Enterprise,” “One of the 1,000 National Energy-Saving Enterprises,” “Advanced Energy-Saving Enterprise in Shandong Province,” “Model Enterprise for Enterprise Production Management in Shandong Province,” and “Leakage-Free Factory.” Shandong **Zhongnong Runtian Chemical Co., Ltd. is located in the southwest part of ** city, adjacent to the Jingfu Expressway and National Highway 308. It is 1.5 km away from the train station and only 50 km from the provincial capital, Jinan, enjoying favorable geographical conditions and convenient transportation access. V. Overview of the project construction: This is an energy-saving renovation project, and its main renovation components include: 1. The installation of new ammonia recovery and hydrogen extraction systems for off-gases; these systems enable the condensation and recovery of most of the NH3 present in the off-gases from storage tanks during ammonia synthesis, while other gases (such as hydrogen and methane) are sent to waste heat boilers for utilization ； 2. Hydrogen recovery unit utilizing membrane technology, which can separate useful components such as hydrogen and carbon dioxide before returning them to the system for ammonia synthesis ； And the gases such as methane, nitrogen, and carbon monoxide are recovered and sent to the waste heat utilization boiler ； 3. Carbon-propylene flash vapor pressure swing adsorption unit: By using this unit, the gases containing methane, nitrogen, carbon monoxide, etc., after separation can be fed into the production system, thereby increasing the ammonia output of the system and improving the environment ； 4. Lithium bromide refrigeration units: With this system, the circulating hot water (desalinated water) from the urea absorption cooler can be used as a heat source to feed the lithium bromide unit, thereby producing refrigerant water for cooling the decarburized propylene liquid. This device converts hot water directly into cooling capacity, not only saving a large amount of circulating cooling water but also significantly reducing the temperature of the decarburization carbon propylate solution compared to before, thereby improving the decarburization effect ； 5. Combustible gases such as the gas used for gas generation during the production process, the exhaust gas from the ammonia storage tank after passive ammonia recovery, and the exhaust gas from hydrogen recovery, along with the slag from the gas generation furnace, are recycled and sent to waste incineration furnaces and a 50 t/h waste heat boiler. This allows for the recovery of waste heat and the generation of steam, which is then supplied to the newly installed 6000 kW backpressure steam turbine generator set. The steam pressure is reduced from 3.5 MPa to 1.2 MPa, the pressure required for the urea production process, and this steam is delivered to various units that use steam in urea production ； The electricity generated is used for the company’s urea production system ； A newly installed B0.16-1.27/0.49 industrial steam turbine drives the circulation water pump; the pressure is reduced from 1.2 MPa to 0.4 MPa for use in methanol distillation ； The boiler feed pump is driven by the newly installed B0.16-1.27/0.3 industrial steam turbine; it reduces the pressure of the steam from 1.2 MPa to 0.3 MPa, which is then sent to the gas generation system for use as a gasifying agent ； 6. The excess carbon dioxide gas from the ammonia synthesis plant is used to produce food-grade carbon dioxide; this plant recovers the surplus carbon dioxide and, through processes such as desulfurization and drying, produces food-grade carbon dioxide ； 7. Urea auto-stripping system: This device overcomes the problems associated with the original production process, such as high steam consumption, high temperature of the outlet gas, and difficulties in increasing the production capacity; it improves the degree of decomposition in the first stage and reduces the recovery load on the low-pressure system. As the outlet gas temperature decreases, steam consumption can be reduced by 0.2 tons per ton of urea produced ； 8. Urea deep desorption unit: This unit is used to treat the desorbed liquid containing NH3, CO2, and urea from the original desorption tower, as well as the dilute ammonia water from the synthesis system, so as to reduce the concentration of substances in the wastewater to below 10PPm. The treated water can be reused as soft water for the ammonia synthesis process and as makeup water for circulating water, thereby improving the company’s environmental performance ； 9. The micro-vortex treatment device for gas generation cycle water, the optimization and modification of water balance, the accompanying cycle water purification devices, as well as the fire protection systems for such projects, can all adsorb, separate, and remove impurities from the gas generation cycle water. This helps to address the issue of large-scale discharge of this water, enabling \"zero discharge\" of it” ； 10. A new set of micro-vortex clarification devices was installed to feed the primary water into the reaction chamber of the clarification tower. Thanks to the \"micro-vortex\" effect created by the multiple layers of reaction trays, the small particles in the water are gradually enlarged into larger flocs, which then absorb the impurities present in the primary water. After separation and sedimentation via inclined tubes, these flocs are discharged. It can significantly improve the quality of the raw water, reducing the treatment costs in subsequent processes. 11. For the project’s auxiliary substations and electrical energy-saving upgrades, new on-site compensation DFJ—B3 comprehensive power savers are installed; the original high-loss SL7 transformers are replaced with new S11 transformers, and AC variable-frequency speed control technology is employed ； 12. The project is equipped with a DCS system, which is used to monitor the production process. Under normal conditions, operators in the control room can ensure the continuous and safe operation of the production equipment, thereby achieving an automation level that is among the highest for similar installations in China. VI. Rational energy use assessment: This project is an energy system optimization initiative for the urea production process, and it is divided into 12 sections. The various units involved in this project, by drawing on advanced foreign technologies as well as practical experience from similar domestic installations, actively adopt new processes, equipment, technologies, and materials in order to further reduce the consumption of water, electricity, steam, and fuel during the production process, thereby minimizing the energy consumption associated with the products. 1. The passive ammonia recovery unit utilizes cryogenic technology developed by the Institute of Physics, Chinese Academy of Sciences; it recovers ammonia from the emitted off-gases, condenses it into liquid ammonia, and feeds it into the production system. The other gases resulting from ammonia recovery (hydrogen, methane, etc.) are sent to waste heat boilers for energy utilization, which not only reduces the emission of harmful gases and improves the environment but also increases ammonia production through the recycling of liquid ammonia, thereby reducing energy consumption per unit of product. It complies with **policies on energy conservation and emission reduction. Basic data for energy conservation calculations: The ammonia synthesis capacity of this project is 180,000 tons per year, the urea production capacity is 300,000 tons per year, and the price of liquid ammonia is 2,100 yuan per ton ； Circulating water at 0.2 yuan per ton ； Electricity costs 0.365 yuan per kilowatt-hour, while air costs 0.2 yuan per cubic meter ； Water cost: 2.2 yuan per ton ； Deoxygenated deionized water: 5 yuan per ton ； Steam at 100 yuan per ton ； Assuming 7,200 hours per year, and that the energy consumption per ton of liquid ammonia is 46.89 GJ, the equivalent value in standard coal is 1.6 tons. The conversion factors are as follows: 1,000 kW of electricity, 1 ton of steam, 1,000 tons of water, 1 ton of ammonia, and 1,000 m3 of carbon dioxide correspond to X tons of standard coal, where X is 3.66 for liquid ammonia, 0.1286 for electricity, 0.086 for steam, 1.6 for water, and 0.214 for carbon dioxide. For energy savings calculations: if 1 ton of liquid ammonia is recovered, it equates to 11 kg of ammonia recovered. Thus, the annual amount of liquid ammonia recovered is 180,000 × 0.011 = 1,980 tons, which corresponds to 1,980 × 1.6 = 3,168 tons of standard coal. 2. New hydrogen recovery unit: The new hydrogen recovery unit utilizes membrane technology; driven by the pressure difference across the membranes and varying permeation rates, it recovers hydrogen and carbon dioxide from the inert gases emitted periodically by the ammonia synthesis tower and feeds them into the production system to increase the amount of ammonia produced. It also recovers gases such as methane, nitrogen, and carbon monoxide for use in generating heat in waste heat boilers. It increased the production of synthetic ammonia and reduced the consumption per unit of product, in line with the provisions of the \"China Energy Conservation Technology Policy Outline (2006)\) regarding the research and development and promotion of membrane technology applications in areas such as gas separation, wastewater treatment, and electrolysis. Calculation of energy-saving benefits: According to the feasibility study report, the amount of energy saved can be calculated as follows: The hydrogen recovered can be converted into liquid ammonia; with 1 ton of liquid ammonia equivalent to 10 kg of hydrogen, the annual amount of liquid ammonia recovered is 180,000 × 0.01 = 1,800 tons. Multiplying this by 1.6 gives 2,880 tons of standard coal equivalent. The amount of liquid ammonia produced per hour is 1,800 / 7,200 = 0.25 tons per hour. The total cost per hour is 114.425 × 1.3 = 148.525 yuan. The cost of producing 1 ton of ammonia is 148.525 / 0.25 = 594.1 yuan. The annual benefit of the facility is 1,800 × (2,100 – 594.1) = 2.7106 million yuan. Converting this to an equivalent amount of liquid ammonia: 2.7106 × 10,000 / 2,100 = 1,290.76 tons. Converting this to standard coal equivalent: 1,290.76 × 1.6 = 2,065.22 tons. 3. The propylene flash vapor pressure swing adsorption unit utilizes this technology to recycle the propylene flash vapor that would otherwise be released into the atmosphere. The gases separated, including methane, nitrogen, and carbon monoxide, are sent back into the production system, thereby increasing the ammonia output and reducing energy consumption. This approach complies with the provisions of the Medium- and Long-Term Energy Conservation Plan, which calls for the use of pressure swing adsorption technology in small and medium-sized ammonia synthesis plants to reduce energy consumption. 4. Lithium bromide refrigeration unit: In this project, a lithium bromide refrigeration unit is used, with the circulating hot water from the urea absorption cooler (desalinated water at around 90°C) serving as the heat source. This water is fed into the lithium bromide unit to produce chilled water, which is then used to cool the decarburized propylene liquid. This system converts the hot water that would otherwise be discharged directly into the circulating water into cooling capacity, thereby saving a large amount of circulating cooling water. It also allows the temperature of the decarburized propylene liquid to drop significantly compared to before, improving the decarburization effect. It complies with the provisions of the \"China Energy Conservation Technology Policy Outline (2006)\), which calls for the promotion of technologies for recovering and utilizing waste heat, waste pressure, and waste energy generated during production processes. It adheres to the principle of \"gradual utilization and high-efficiency use\", giving priority to using high-quality waste heat and energy for power generation or mechanical work, while using low-temperature waste heat for air conditioning, heating, or domestic heating purposes. Energy savings calculation: By using lithium bromide chillers to produce chilled water for the propylene decarboxylation process, 400 m3/h of urea cycle water can be saved. The propylene decarboxylation unit allows for a savings of 1.5 million kcal, and two ice makers are required; each of these ice makers has a power capacity of 300 kW. Cost structure after the renovation: (per hour) Cost component, consumption indicator, unit cost (yuan): Circulating water – 400 tons at 80 yuan; Electricity – 70 kWh at 25.55 yuan; Labor costs – 4 yuan; Administrative expenses – 2.4 yuan; Maintenance costs – 4 yuan; Depreciation (over 5 years) – 15 yuan; Others – 2 yuan. Total: 132.95 yuan. By using lithium bromide refrigeration units to produce chilled water for carbon propylene decarboxylation, the carbon propylene decarboxylation system can save 1.5 million kcal. Two ice makers are required, each with a power capacity of 300 kW. Cost structure before the renovation: (per hour) Cost component, consumption indicator, unit cost (yuan): Circulating water – 400 tons at 80 yuan; Electricity – 600 kWh at 219 yuan; Labor costs – 5 yuan; Administrative expenses – 2.6 yuan; Maintenance costs – 4.5 yuan; Depreciation (over 5 years) – 30 yuan; Others – 2 yuan. Total: 343.1 yuan. Annual electricity savings from lithium bromide refrigeration units: (600 – 70) × 7200 = 3.816 million kWh. Annual equivalent amount of standard coal: 3.816 × 3.66 = 1,396.66 tons. 5. Waste heat recovery system for purge gas and cascade utilization of steam (50-ton waste heat boiler): This system recovers combustible gases such as the purge gas used in gas production, the gas released from ammonia storage tanks after ammonia recovery, and the exhaust gas from hydrogen recovery, as well as the slag from the gas production furnace. These materials are sent to a waste mixed combustion furnace and a 50-ton/h waste heat boiler to recover waste heat and generate steam, which is then supplied to a 6,000 kW backpressure steam turbine generator set. The steam pressure is reduced from 3.5 MPa to 1.2 MPa, the pressure required for the urea production process, and the steam is sent to various stations where it is used in urea production ； The electricity generated is used internally by the company’s urea production system. The 0.4 MPa low-pressure steam required for methanol distillation is obtained by reducing the pressure of steam from a 1.2 MPa pipeline system, which is fed into the B0.16-1.27/0.49 industrial steam turbine to drive the circulation water pump ； The boiler feed pump is driven by the B0.16-1.27/0.3 industrial steam turbine; it reduces the pressure of the steam from 1.2 MPa to 0.3 MPa, and the low-pressure steam at 0.3 MPa is sent to the gas generation system for use as a gasifying agent. The steam pressure reduction process enables the hierarchical and comprehensive utilization of energy, replacing two 160kW motors and saving electrical power for pump operation. It complies with the provisions of the \"China Energy Conservation Technology Policy Outline (2006)\), which calls for the promotion of technologies for recovering and utilizing waste heat, waste pressure, and waste energy generated during production processes. It adheres to the principle of \"gradual utilization and high-efficiency use\", giving priority to using high-quality waste heat and energy for power generation or mechanical work, while using low-temperature waste heat for air conditioning, heating, or domestic heating purposes. It conforms to the principle of using steam pumps in place of electric pumps and leveraging low-pressure steam to save electrical energy. It meets the development requirements for the hierarchical utilization of heat as stipulated in the Guidelines for the Comprehensive Utilization of Resources during the 11th Five-Year Plan period. Energy savings calculation: By utilizing the heat from the three types of waste gases (ammonia recovery exhaust gas, hydrogen recovery exhaust gas, and blowing exhaust gas) as well as the gas generation furnace slag, 20 t/h more steam can be produced compared to before the renovation, thereby reducing the need to purchase steam externally. Composition of production costs: (per ton of steam) Cost components and associated expenses (in yuan): Soft water – 1.1 m3 at 5.5 yuan; three types of waste gases – 24 yuan; waste residues – 15 yuan; labor costs – 0.2 yuan; administrative expenses – 0.6 yuan; maintenance costs – 1.5 yuan; depreciation – 10.375 yuan; others – 3 yuan. Total cost: 59.375 yuan. Steam saved: 20 × 7200 = 144,000 tons. Equivalent amount of standard coal: 144,000 × 0.1286 = 18,518.4 tons of standard coal. Annual electricity generation from cascaded use of steam: 6000 × 0.8 × 7200 = 34.56 million kWh. Annual energy savings: 34.56 × (0.365 – 0.24) × 10,000 / 0.365 = 11.8356 million kWh. Equivalent amount of standard coal for these savings: 11.8356 × 3.66 = 4331.83 tons. Energy savings from the circulating water pump and the feed water pump: 320 X 0.8 X 7200 = 1.8432 million kWh, which is equivalent to 674.611 tons of standard coal. 6. Food-grade carbon dioxide production facility: During the urea production process, this company generates excess carbon dioxide gas; a new recovery system has been installed to capture this excess carbon dioxide, which is then processed through desulfurization and drying to produce food-grade carbon dioxide. Excess carbon dioxide is recovered, emissions are reduced, corporate efficiency is increased, meeting the requirements for **energy conservation and emission reduction. It meets the 11th Five-Year development goal set out in the Guidelines on Comprehensive Utilization of Resources, which calls for the resource-based recovery and utilization of carbon dioxide during the production process. By making full use of the carbon dioxide emitted during the decarbonization process, it has been calculated that the production of one ton of food-grade carbon dioxide can result in a reduction of approximately 650 Nm3 of carbon dioxide emissions. This facility is capable of producing 33,000 tons of food-grade carbon dioxide per year, thereby reducing carbon dioxide emissions by around 21.45 million Nm3. 7. The urea auto-stripping system: The original urea plant’s first-stage decomposition system used a pre-separation process, which resulted in high steam consumption and high temperatures of the outlet gases, making it difficult to increase the plant’s production capacity further. This project was modified using a urea auto-stripping system to increase the decomposition rate in the first stage and reduce the recovery load on the low-pressure system. As the outlet gas temperature decreases, steam consumption can be reduced by 0.2 tons per ton of urea produced. Through process modifications, this project can increase production capacity and reduce steam consumption, in line with the principles of energy conservation and emission reduction. 8. The urea deep desorption unit treats the desorbed liquid containing NH3, CO2, and urea from the primary desorption tower, as well as the dilute ammonia water from the synthesis system, through urea deep desorption. This improves the recovery rate of ammonia nitrogen in the treated liquid, and the wastewater resulting from this process is reused as soft water for ammonia synthesis and as makeup water for circulation systems, thereby reducing the environmental pressures on enterprises. Ammonia nitrogen and water were recovered, reducing emissions and in line with energy conservation and emission reduction policies. This unit can deeply desorb 40 m3/h of wastewater; after desorption, approximately 50 m3/h to 55 m3/h of water is available for use as soft water in the ammonia synthesis gas production process (13 m3/h) and as make-up water for circulating water. Thus, 40×24×300 = 288,000 m3 of water can be saved per year; of this amount, 93,600 m3 is soft water. In-depth urea desorption can help save water – 40 m3/h can be saved through this method, while in-depth urea desorption can also help save desalinated water: 13 m3/h. 9. Micro-vortex treatment devices for gas generation cycle water, along with optimizations for water balance. The gas generation circulating water is fed into the reaction chamber of the clarification tower. The phosphorus-based chemicals previously used have been replaced with HW-1, a multi-functional circulating water scale and corrosion inhibitor. Thanks to the \"micro-vortex\" effect created by the multiple reaction tower trays, these chemicals help to gradually increase the size of small particles into larger flocs, which in turn absorb the suspended impurities present in the gas generation circulating water. These impurities are then separated and removed through inclined tubes. The treated water enters the cold water tank for gas generation circulating water, from where it is pumped into the cooling system used in gas generation processes. This device completely solves the problem of large-scale discharge of gas generation circulating water, achieving \"zero discharge\" of such water. This project uses a new type of treatment agent that leverages the effect of \"micro-vortices\" for water treatment, achieving \"zero discharge\" of the gas generation cycle water and thus complying with regulations on energy conservation and emission reduction. It is in line with the Guidelines for the Comprehensive Utilization of Resources during the 11th Five-Year Plan period, which call for the development of the resource utilization of waste streams from industries such as papermaking, food fermentation, printing and dyeing, leather processing, chemicals, textiles, and the processing of agricultural and livestock products, with an emphasis on recovering usable resources ； Requirements for promoting the recycling of industrial wastewater. 10. Supporting circulating water purification equipment and project fire protection. Due to the poor quality of the primary water in the company, a large amount of sediment accumulates in the primary water pipelines, resulting in poor quality of water used for replenishing the circulating water, difficulties in reverse osmosis pre-treatment, high amounts of wastewater from the circulating water system, frequent backwashing of filters, and waste of primary water. A new set of micro-vortex clarification devices has been installed, which feed the primary water into the reaction chamber of the clarification tower. Thanks to the \"micro-vortex\" effect created by the multiple layers of reaction trays, drugs are used to gradually increase the size of small particles into larger flocs, which then absorb the impurities present in the primary water. After separation and sedimentation via inclined tubes, the purified water is discharged. This device can significantly improve the quality of raw water and reduce the processing costs in subsequent steps. The treated water enters the clean water tank and is pumped into the production system by a clean water pump. This project uses a new type of treatment agent that relies on the effect of \"micro-vortices\" for water treatment, thereby improving water quality and increasing water utilization while reducing waste, in line with regulations on energy conservation and emission reduction. The treatment of circulating water and primary water using micro-vortex technology results in a savings of 152.2 m3/h in primary water usage. The use of condensate and desalinated water further leads to a savings of 35 m3/h in desalinated water consumption. 11. The project includes upgrades to the substation and electrical systems for energy savings: old SL7 transformers with high loss rates are replaced by new S11 transformers with lower loss rates. Variable frequency drives are installed on major motor devices, and high-voltage power savers are used to eliminate transient surges in the power distribution network, thereby reducing the increased energy consumption caused by such transients and improving the overall efficiency of the electrical system. These measures also protect end devices from being affected or damaged, offering both energy-saving and safety benefits. High-efficiency, long-lasting gas discharge lamps are used for lighting, variable frequency drives are employed to control the speed of motors that require it, and energy-efficient components are used in the control equipment of the secondary circuits. It is in line with the \"Outline of China’s Energy-Saving Technology Policy (2006)\), which calls for the development and promotion of high-efficiency mechanical and electrical equipment, as well as the use of energy-saving distribution equipment and accessories such as S11-type transformers, low-loss wires, and various fittings. Develop and promote variable-frequency speed control technologies and devices, as well as internal-feedback chopper speed control technologies and devices. Research and develop energy-saving and efficient electric motors. Provisions regarding the use of cold-rolled silicon steel sheets in place of hot-rolled silicon steel sheets for power motors and variable-frequency motors integrated with frequency converters. It complies with the provisions in the \"Guidance Catalogue for Industrial Structure Adjustment (2005 edition)\) regarding the development and application of energy-saving technologies based on variable-frequency speed control, which are classified as areas worthy of encouragement. It complies with the provisions of the Medium- and Long-Term Special Plan for Energy Conservation, which calls for the implementation of optimized upgrades to high-efficiency energy-saving fans, pumps, and compressor systems in industries such as coal, power, non-ferrous metals, and petrochemicals, as well as the promotion of variable frequency speed control and automated system control technologies. Estimation of energy-saving benefits (1) Transformer upgrades: The transformers to be updated are listed in the table below. Sequence, Model, Capacity (kVA), High Voltage/Low Voltage (kV), Quantity, Unit Price (10,000 yuan), Total Price (10,000 yuan): 1. SF11-8000/35/68, 000, 35/6, 290, 180; 2. S11-2000/35, 2000, 35/0.41, 19.5, 19.5; 3. S11-1600/35, 1600, 35/0.41, 17, 17; 4. S11-1250/35, 1250, 35/0.41, 16, 16; 5. S11-800/68, 000, 6/0.44, 11, 44; 6. S11-1250/6, 1250, 6/0.42, 14.5, 29; 7. S11-500/6, 500, 6/0.42, 7.2, 14.4. Total: 13 units, total cost of 319.9 million yuan. The above-mentioned transformers were evaluated using the Total Cost of Ownership method established by the International Copper Association; the payback period for each transformer is approximately 2 years. 1) Comparison of the total cost of ownership for S11—800/6 and S7—800/6 transformers. With a service life of 20 years, the transformer is used in a fertilizer factory where operation follows a three-shift system, and its load rate is 75%. For the S11—800/6 type, 800 kVA transformer, the loss values including reactive power losses are as follows: No-load loss PNL = P0 + KQ0 = P0 + K × (I0%Se/100) = 1.40 + (0.1 × 0.008 × 800) = 2.04 kW. Load loss PLL = Pf + KQf = P + K × (U%Se/100) = 7.5 + (0.1 × 0.045 × 800) = 11.09 kW. Similarly, for the S7—800/6 transformer, the no-load loss is 2.5 kW and the load loss is 13.49 kW. Calculation of annual electricity savings for the S11 type 10 kV, 800 kVA transformer (with an annual operating time of 300 days): Annual electricity savings = (Total losses of S7 transformer – Total losses of S11 transformer) × Annual operating time = [(13.49 + 2.5) – (11.09 + 2.04)] × 300 × 24 = 20,592 kWh. For 4 such transformers, the total annual electricity savings amount to: 20,592 kWh × 4 = 82,368 kWh. 2) Calculation of annual electricity savings for the S11 type 10 kV, 1250 kVA transformer (annual operating time: 300 days): Annual electricity savings = (Total losses of S7 transformer – Total losses of S11 transformer) × Annual operating time = [(16.50 + 2.65) – (14.50 + 2.35)] × 300 × 24 = 16,560 kWh. For 2 such transformers, the total annual electricity savings amount to: 16,560 kWh × 2 = 33,120 kWh. 3) Calculation of annual electricity savings for the S11 type 10 kV, 500 kVA transformer (annual operating time: 300 days): Annual electricity savings = (Total losses of S7 transformer – Total losses of S11 transformer) × Annual operating time = [(6.90 + 1.08) – (5.10 + 0.96)] × 300 × 24 = 13,824 kWh. For 2 such transformers, the total annual electricity savings amount to: 13,824 kWh × 2 = 27,648 kWh. 4) Calculation of annual electricity savings for the S11 type 35 kV, 8000 kVA transformer (annual operating time: 300 days): Annual electricity savings = (Total losses of S7 transformer – Total losses of S11 transformer) × Annual operating time = [(41.00 + 8.20) – (35.00 + 7.40)] × 300 × 24 = 48,960 kWh. For 2 such transformers, the total annual electricity savings amount to: 48,960 kWh × 2 = 97,920 kWh. 5) Calculation of annual electricity savings for the S11 type 35 kV, 2000 kVA transformer (annual operating time: 300 days): Annual electricity savings = (Total losses of S7 transformer – Total losses of S11 transformer) × Annual operating time = [(19.80 + 3.40) – (16.50 + 3.10)] × 300 × 24 = 25,920 kWh. 6) Calculation of annual electricity savings for the S11 type 35 kV, 1600 kVA transformer (annual operating time: 300 days): Annual electricity savings = (Total losses of S7 transformer – Total losses of S11 transformer) × Annual operating time = [(19.50 + 2.65) – (15.50 + 2.60)] × 300 × 24 = 29,160 kWh. 7) Calculation of annual electricity savings for the S11 type 35 kV, 1250 kVA transformer (annual operating time: 300 days): Annual electricity savings = (Total losses of S7 transformer – Total losses of S11 transformer) × Annual operating time = [(16.30 + 2.2) – (12.50 + 2.20)] × 300 × 24 = 27,360 kWh. Total electricity savings: 82,368 + 33,120 + 27,648 + 97,920 + 25,920 + 29,160 + 27,360 = 323,496 kWh. (2) Installation of frequency converters on major motor equipment: The total capacity of these devices is 597 kW; their annual power consumption is approximately 3.22 million kWh. Assuming a power-saving rate of 15% due to the use of frequency converters, the annual electricity savings from this measure will be 483,000 kWh. (3) Installation of power savers for high-voltage motors: Equipment details: Motor model, place of manufacture, quantity, power saver model, unit price, and total cost are listed below. Large lean solution pump: JSQ1512-4, Shanghai Electric Machinery Factory; 3 units, DFJ-B3-HT6-100K9, unit price: 10,000 yuan, total cost: 30,000 yuan. Chiller: Y400-2, Shanghai Electric Machinery Factory; 5 units, DFJ-B3-HT6-75K8, unit price: 3720 yuan, total cost: 18,600 yuan. Clean water pump: JS137-4, Zhangdian Electric Machinery Factory; 4 units, DFJ-B3-HT6-75K8, unit price: 3720 yuan, total cost: 33,488 yuan. Water pump: Y355-4, Zhangdian Electric Machinery Factory; 5 units, DFJ-B3-HT6-75K8, unit price: 3720 yuan, total cost: 18,600 yuan. Rotary machine: Y5003-10, Jiangsu Dazhong Electric Machinery Factory; 3 units, DFJ-B3-HT6-75K8, unit price: 3720 yuan, total cost: 25,116 yuan. Circulating machine: Y450-8, Jiangxi Electric Machinery Factory; 2 units, DFJ-B3-HT6-75K8, unit price: 3720 yuan, total cost: 16,744 yuan. Large fan: JK500-2, Shenyang Electric Machinery Factory; 3 units, DFJ-B3-HT6-75K8, unit price: 3720 yuan, total cost: 25,116 yuan. Small fan: JK134-2, Shanghai Electric Machinery Factory; 3 units, DFJ-B3-HT6-75K8, unit price: 3720 yuan, total cost: 25,116 yuan. Fresh air fan: JK136-2, Zhangdian Electric Machinery Factory; 2 units, DFJ-B3-HT6-75K8, unit price: 3720 yuan, total cost: 16,744 yuan. Small lean solution pump: JSQ147-4, Shanghai Electric Machinery Factory; 3 units, DFJ-B3-HT6-75K8, unit price: 3720 yuan, total cost: 25,116 yuan. New circulating machine: Y450-8, Wuxi Electric Machinery Factory; 2 units, DFJ-B3-HT6-75K8, unit price: 3720 yuan, total cost: 16,744 yuan. In total, there are 35 units requiring installation. Installation costs amount to 2,952,040 yuan; the 5% surcharge brings this figure to 147,602 yuan. Thus, the overall cost comes to 2,952,040 + 147,602 = 3,099,642 yuan. 1) Electricity savings achieved by using the FJ-B3-HT6-75K power savers for high-voltage motors: Based on the economic equivalent of reactive power, with a value of 0.1 and an annual operating time of 7,200 hours, the annual electricity savings amount to: 0.1 × 7,200 = 1,173,120 kWh/year. 2) Electricity savings achieved by using the FJ-B3-HT6-100K power savers for motors: Using the same calculation method, the annual electricity savings amount to: 0.1 × 7,200 = 130,947 kWh/year. For 3 such units, the total annual electricity savings reach 130,947 × 3 = 392,841 kWh/year. Overall, the total annual electricity savings are approximately 1.565961 million kWh. The combined effect of all three measures results in a total electricity saving of 2.372457 million kWh. This corresponds to 2.372457 × 3.66 = 868.319 tons of standard coal. 12. The project also includes a DCS system. For this project, namely the 300,000 tons/year urea production facility optimization project carried out by Shandong **Zhongnong Runtian Chemical Co., Ltd., the scope of automation design includes four gas generation furnaces, waste heat recovery for the blowing air, expansion and renovation of the urea production unit, ammonia recovery and hydrogen recovery, as well as the renovation of the ammonia synthesis process using the \"Φ2000 and Φ1800 dual-tower dual-waste-heat-exchanger technology\". The 50t/h mixed-fuel furnaces, 6000-kilowatt generator sets, as well as the ammonia and hydrogen recovery systems and gas generation furnace installations all utilize Zhejiang University’s ZHKONDCS (JX-300X) system ； The urea plant uses HONEYWELL’s DCS from the United States for monitoring, recording, and operation, thereby enhancing the level of automation in the system. It is in line with the Medium- and Long-Term Special Plan for Energy Conservation, which emphasizes the combination of energy conservation with structural adjustment, technological progress, and improved management. It involves adjusting the industrial structure, product structure, and energy consumption pattern, phasing out outdated technologies and equipment, upgrading traditional industries with high-tech and advanced applicable technologies, promoting the optimization and upgrading of the industrial structure, and raising the overall technical level of the industries. It meets the **relevant requirements for improving the automation level of the equipment. The project is expected to achieve energy savings of 36,673.82 tons of standard coal. VII. Issues and Recommendations 1. It is recommended to use high-efficiency, new-type insulation materials to insulate thermal equipment and pipelines. 2. It is recommended to select energy-efficient lighting fixtures in accordance with the requirements set out in the \"National Energy Conservation Technology Policy Outline (2006)\) for promoting green lighting technologies and products. 3. It is recommended to develop high-performance reactive power compensation devices in accordance with the \"Outline of China’s Energy Conservation Technology Policies (2006)\“. Transformations are required to promote the use of adjustable low-voltage reactive power compensation devices, as well as high-voltage advanced reactive power compensation devices (such as SVCs and SVGs). 4. It is recommended to strengthen scientific operation management after the project is implemented, to ensure the efficient operation of high-quality equipment, minimize heat losses, and achieve higher economic benefits. VIII. Evaluation Conclusion: This project implements comprehensive utilization of steam, water, waste gas, and waste residues in the urea production system, recovering the resources that are otherwise emitted. By optimizing the system’s energy management, it not only enables the efficient utilization and value addition of waste heat and pressure but also helps to protect the environment and reduce pollution. Replace old transformers with new, energy-efficient ones. Carry out energy-saving upgrades to high-power, high-energy-consuming electrical equipment in the production system such as air compressors, fans, and water pumps, as well as some low-voltage motors; install comprehensive energy-saving devices. For those equipment motors that require frequent adjustment and high precision, install frequency converters, and use frequency-controlled motors for air conditioning and ventilation systems in order to adjust the air volume as needed and thus save a large amount of electricity. This project employs energy system optimization techniques, that is, it uses advanced processes, technologies, and equipment to transform the existing production system. This enables optimal allocation of resources related to the production system, as well as hierarchical and multiple uses of energy based on its quality. It also ensures that the energy utilization process is matched to the energy demands, thereby improving energy efficiency. In summary, this energy system optimization project falls within the scope of the **Top 10 Energy-Saving Projects**; it is a project aimed at the comprehensive utilization of resources, and it complies with **industrial policies**, as well as **requirements regarding energy conservation and emission reduction**, in accordance with the relevant regulations of Shandong Province and this city ； It meets the requirements of China’s energy-saving technology policy framework and the medium- to long-term energy-saving plans ； The total energy consumption and types of energy used in the project are reasonable ； The project employs advanced process technologies ； Implemented the **catalog of devices and products explicitly recommended for promotion or elimination ； After the implementation of this project, the material consumption per unit of product can be reduced significantly; it is expected that the project will result in energy savings of 36,673.82 tons of standard coal. Assessment Responsible Person: Date