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【Haichuan: Learning from Others’ Experiences】Accelerating the domestic substitution of equipment and its components to improve quality and efficiency

2024-05-13View Original

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Localizing equipment and its accessories is an important method to improve quality and efficiency. In the renovation project of Line 235 at the polypropylene plant of Dushanzi Petrochemical Company, the main equipment was replaced from imported units to domestic alternatives, reducing costs by more than half.   Construction on this project began in May 2023, and it is expected to be completed and put into operation by August 30 of this year. The key equipment involved in the project, such as the exhaust gas recovery compressor, quench liquid centrifugal pump, and main catalyst pump, are all of domestic manufacture. Currently, 95% of the equipment has arrived, and 90% has been installed.   At Dushanzi Petrochemical, actively promoting the use of domestic equipment and components, as well as domestic production of various chemicals, and ensuring that all new projects make use of domestic materials, has become an important way to improve quality and efficiency, accelerate the economic ‘internal circulation’, and pursue a path of high quality, high efficiency, and sustainable development.   In 2023, the Polyolefins Department 2 of Dushanzi Petrochemical completed the localization of components for units such as centrifugal compressors, extruders, and reciprocating compressors, saving over 10 million yuan in costs ; The gear pumps and universal couplings used in the No. 34 extruder of Polyolefins Department 1 have been replaced with domestic alternatives, saving over 2 million yuan in costs ; The bearing bushes for 5 key units in the Ethylene Unit 2 and Polyolefins Unit 2 were replaced with domestic alternatives, saving over 4.6 million yuan in costs… That year, the company managed to reduce its annual expenses by 66.43 million yuan through the use of domestic equipment and accessories.   In addition to the costs of equipment accessories, the costs of the three chemical reagents are also an important part of the operating costs of the plant. Adhering to the principles of continuous progress and cautious implementation, Dushanzi Petrochemical has kept working on the introduction of new agents and the substitution with domestic alternatives, achieving significant results. According to statistics, in 2023 the company used domestically produced metallocene polyethylene additives in its full-density polyethylene production facility, as well as antioxidants in its styrene-butadiene rubber production facility; furthermore, it utilized furan derivatives, which resulted in annual cost savings of 3.6 million yuan, 4.32 million yuan, and 20.7 million yuan respectively.   At present, making extensive use of proprietary technologies and domestically produced equipment to reduce production costs, decrease reliance on external sources, ensure operational economic security, promote the transformation and upgrading of the refining industry toward higher levels, and continuously enhance the capacity to safeguard **energy security has become the development direction for Dushanzi Petrochemical.   In 2022, the Polyolefins Department 2 of Dushanzi Petrochemical utilized domestic catalysts to develop new polyethylene products. This not only enabled the seamless transition between two different grades of products but also ensured stable and controlled operation of the plant as well as satisfactory product quality, laying a solid foundation for future polyethylene production and the development of metallocene polyethylene products using domestic catalysts. In March this year, the company completed the localization replacement of the extruder and dryer units in the styrene-butadiene rubber production line at its rubber division. This initiative not only reduced procurement costs from 30.3 million yuan to 3.44 million yuan, but also resolved the issue of abnormal friction between the screw and the cylinder of the extrusion dehydrator during rotation, thereby improving both the operational condition of the equipment and the stability of product quality.   In addition, Dushanzi Petrochemical has fulfilled its responsibilities as a central state-owned enterprise in building a modern industrial system; it has successively developed and produced a range of key products that serve as substitutes for imported items, such as specialty materials for pipes, metallocene films, and environmentally friendly rubbers. These products have provided strong support for downstream enterprises in replacing imported raw materials with domestic alternatives.   On April 23, the procurement contract for Unit 3 of the ethylene plant in the Tarim Phase II project of Dushanzi Petrochemical was successfully signed. The fully electrically driven ethylene plant with a capacity of three million tons, purchased through this contract, is the first of its kind in China. It holds great significance for Dushanbe Petrochemical in promoting the use of domestic alternatives, in establishing itself as a hub for original petrochemical technologies, and in creating a \"high-value version\" of such plants that enhances efficiency and productivity.   This year, Dushanzi Petrochemical also plans to replace imported components such as touchscreens on DC panels, batteries, relay protection devices, control valve accessories, and imported instruments with domestic alternatives, which is expected to save 9.46 million yuan in costs.   “The shutdown for maintenance in 2024 is about to begin. We will complete the localization of 70 pieces of equipment and 80 components, and we will work with leading domestic equipment manufacturers to conduct data mapping on around 180 imported pieces of equipment and more than 2,700 components, thereby laying the foundation for the continued localization of these parts in the future.” ”Qin Tao, deputy manager of the Mechanical Equipment Department at Dushanzi Petrochemical, said.

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