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【Learning from Others’ Experiences】Maoming Petrochemical’s renovation of old steam turbines has resulted in annual savings of 34,600 tons of standard coal across the two units

2025-04-19View Original

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The Power Department of Maoming Petrochemical carried out a back-pressure extraction transformation on Unit 1, the double-extraction condensing unit in the refining area, and applied a \"fully reactive\" flow design technique to transform Unit 3; the two steam turbines together save a total of 34,600 tons of standard coal per year.   Turbines No. 1 and No. 3 in Workshop 1 of the Power Department at Maoming Petrochemical, as key power generation units in the refining area, have been in operation for many years; they suffer from issues such as equipment aging and declining energy efficiency.   In recent years, under the guidance of the **\"dual carbon\" strategy, Maoming Petrochemical has thoroughly investigated the potential for energy savings and emission reduction in its units, and launched renovation projects for the flow systems of Turbines No. 1 and No. 3 in the refining area. During the renovation planning phase, Maoming Petrochemical conducted extensive research to learn from others’ strengths and address its own weaknesses. Adhering to the principles of advanced technology and economic efficiency, it adopted an innovative renovation approach of \"retaining the framework while upgrading the core components,\" and developed customized renovation packages based on the different internal structures of the units.   The renovation process is like giving an old house a high-end interior makeover. Maoming Petrochemical carried out a back-pressure conversion on Unit 1, a double-suction condensing unit. Adopting a conversion approach that involved \"customizing a completely new core flow design for each back-pressure operating condition after the conversion,\" it developed a new generation of flow technology while retaining 97% of the original equipment, thereby achieving 100% reuse of the external cylinders and improving safety, economy, and cost-effectiveness. After the renovation, the standard coal consumption for power generation in Unit 1 dropped sharply from 294.5 grams/kWh to 147.11 grams/kWh.   Unit 3 was originally a \"impulse-type\" extraction backpressure unit; the renovation adopted a \"fully reactive\" flow design technique, enabling a more rational distribution of enthalpy drop across various stages and resulting in higher efficiency. Compared to traditional “impulse-type” models, it can increase power generation by 6% under the same suction and discharge conditions. After the renovation, the standard coal consumption for power generation in Unit 3 was 151.04 grams per kilowatt-hour, representing a reduction of 26%.   In addition to modifying the structural design of the turbines, Maoming Petrochemical has also developed a customized flow design platform to ensure seamless integration between old and new equipment ; Innovate the forming process for prefabricated partitions, achieving a precision of 0.01 millimeters for key components ; An intelligent control system was developed, raising the steam utilization rate to 98.5% and improving the unit’s energy-saving efficiency as well as operational reliability.   After the renovation, the two turbine units save a total of 34,600 tons of standard coal per year, which is equivalent to a reduction of 91,000 tons of carbon dioxide emissions. Tests during operation have shown that the reliability of the device remains at 100%, and the precision of steam regulation has improved by 40% compared to before, thereby solving the problem of steam balance in refining units.   Today, this achievement has been successfully replicated in 5 enterprises including Qilu Petrochemical. If implemented across the entire industry, it is estimated that 2 million tons of standard coal can be saved annually, resulting in a reduction of 5.28 million tons of carbon emissions.

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