Shaanxi Xinghua completed dual-system maintenance for the first time

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Last week, as the chemical production facilities at Shaanxi Xinghua Company operated at full capacity to produce qualified products, it marked the successful completion of the first annual maintenance tasks for the two production systems under Yanchang Petroleum Xinghua Company. This dual-system maintenance campaign lasted nearly two months, during which over 3,000 maintenance tasks were completed. It eliminated all potential risks associated with the equipment, and through technical upgrades and process optimizations, it improved the efficiency of the equipment’s operation, thereby restoring new vitality to production and business activities. On June 5, the major maintenance campaign for the 500,000 tons per year coal-based ethanol production facility owned by Yushen Energy & Chemical, which is part of Xinghua Company, was launched. The company focused on key issues such as crack repair in hydrogenation reactors and leakage treatment in gasification oxygen heat exchangers, completed 814 maintenance projects, and resumed operations successfully on July 9. By addressing the issue of degraded performance in carbonylation catalysts through targeted replacement and parameter optimization, the operating efficiency of ethanol production plants has been significantly improved. As another core production segment of Xinghua Company, Xinghua Chemical’s facilities for producing 300,000 tons per year of synthetic ammonia, 300,000 tons per year of methanol, 100,000 tons per year of methylamine/DMF, and 100,000 tons per year of ethanol/HAC (hexyl acetate) began a major system maintenance campaign on June 29. This campaign included 1,908 planned tasks as well as 300 additional tasks, with a focus on key projects such as the renovation of the environmental protection facilities’ desulfurization systems, the repair of rotors in air separation units, and the replacement of catalysts used in the production of methylamine and ethanol. Production was fully resumed on August 6. During the maintenance period, the various centers at Xinghua Chemical worked together to overcome numerous technical challenges. The Youth Commando Team of the Water Operation Center, working in temperatures of 40°C, cleared 300 cubic meters of sludge from the reclaimed water treatment tank, and manually removed 70 cubic meters of collapsed inclined tubes ； The key Party and League members in the Nitro Products Center worked tirelessly to complete the task of filling 300 cubic meters of the liquid nitrogen cooling tank at the Gas Production Center with pearlescent sand ； The oil-cleaning team from the synthesis center climbed into a tank large enough for only one person in order to remove accumulated old oil residue ； The desulfurization unit in the power plant ensures that pollutants remain within specified limits through optimized spray layers. To address the challenges associated with maintenance, the company’s technical team innovatively employed techniques such as the \"3D diagnosis method\" and \"GPS time synchronization\" to overcome technical hurdles such as scaling in the 3,400-meter-long gray water pipeline, as well as the need for millisecond-level timing accuracy in over 10 control systems. Among them, the response speed of the Xinghua Chemical DCS system improved by 40% after the upgrade, and Yushen Energy & Chemical replaced 16 energy-efficient water pumps, which is expected to save 15 million yuan in electricity costs per year. This maintenance effort highlights the three key features of \"safety, sustainability, and intelligence\". Xinghua Company fully implements the \"seven-step method\" for special operations, achieving zero accidents in hot work and operations in confined spaces ； Xinghua Chemical handled 215.1 tons of hazardous waste in a proper manner, while Yushen Energy Chemical promoted a project for the deep dehydration and drying of fine residues, thereby further reducing the amount of solid waste ； In terms of intelligent transformation, Xinghua Chemical has established a \"hourly\" data monitoring system, while the dual-prevention system at Yushen Energy Chemical continues to operate at an \"excellent\" level. At present, Xinghua Company’s dual-system operation is proceeding smoothly; all units have achieved successful commissioning on the first attempt, the system operation parameters are stable, and the product quality meets the required standards. Among them, the output of the Yushen Ethanol Production Facility gradually returned to the planned level, while the Methyl Acetate Facility exceeded its quarterly targets.