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Small innovations to solve big problems ● Problem: A large amount of electrical energy is consumed during the electrolysis of saltwater. The electrolyzers in the caustic soda production unit of Qilu Petrochemical’s chlor-alkali plant are major power consumers; their operating temperature is around 83 degrees Celsius, making it difficult to reach the optimal economic operating temperature of 85 degrees Celsius. ● Innovation: The caustic soda plant has made increasing the operating temperature of the electrolyzers a key task for energy savings. After the pre-period optimization, it is very difficult for the electrolyzer itself to have any further room for direct temperature increase. They adjusted their approach by modifying the idle heat exchanger connected to the main pipeline of the electrolyzer, connecting steam to it, and converting the heat exchanger’s cooling function into a heating function. ● As a result of modifying the heat exchangers, the caustic soda production plant was able to increase the temperature of the electrolyzers by two degrees Celsius, reaching the optimal economic operating temperature of 85 degrees Celsius. With a daily production of over 600 tons of caustic soda, this adjustment results in a daily electricity savings of nearly 5,000 kilowatt-hours. “By modifying the heat exchanger, the temperature of the electrolyzer was increased by two degrees Celsius; based on a production volume of over 600 tons of alkali per day, this results in a daily electricity savings of nearly 5,000 kilowatt-hours. ”On November 15, Han Song, the director of the caustic soda production unit at Qilu Petrochemical’s chlor-alkali plant, did some calculations regarding energy savings. While ensuring safe production, the plant carries out optimization of production and operations as well as analysis of unit costs at various levels, in order to further reduce energy and material consumption. The caustic soda plant has identified the electrolyzer, as a major power consumer, as a key focus for energy-saving efforts; it established a task force to carry out continuous technical research and optimization. “Energy conservation and consumption reduction are ongoing tasks. Based on raising the temperature of the tanks and optimizing the operation of the electrolyzers, the workshop employs new technologies to gradually upgrade these electrolyzers, thereby tapping into further potential for reducing consumption. ”said Yang Ju, head of the Production Technology Department at the chlor-alkali plant. The operating temperature of the electrolyzers in the caustic soda plant is around 83 degrees Celsius, making it difficult to reach the optimal economic operating temperature of 85 degrees Celsius. “Don’t underestimate these two degrees Celsius; saltwater requires a large amount of electrical energy during the electrolysis process. ”Introduced by Han Song. After the pre-period optimization, it is very difficult for the electrolyzer itself to have any further room for direct temperature increase. The task force adjusted its focus and considered whether it would be possible to modify the idle heat exchanger connected to the main pipeline of the electrolyzer by connecting steam to it, thereby changing the heat exchanger’s function from cooling to heating. The workshop was immediately modified; after steam was introduced, the temperature of the tank increased by two degrees Celsius, reaching the optimal economic operating value of 85 degrees Celsius. The on-duty staff regularly check the operation status of the heat exchangers, address any issues that arise promptly, and optimize the operating parameters, thereby achieving the goal of stable and energy-efficient operation of the electrolyzers.