【Haichuan Chemical Salary News】The application of the Cassali synthesis process in China

Inner Mongolia Tianrun Fertilizer Co., Ltd. is the first \"pithead\" urea plant in the western part of the Inner Mongolia Autonomous Region. The company uses world-leading coal-water slurry gasification technology, Swiss Cassali ammonia synthesis technology, and Italian Snam urea synthesis technology to produce urea from coal, with the overall technical level of the project reaching international leading standards. The company is located in the South Coal Chemical Industry Base of Dali Industrial Park, Zhungeer Banner, Ordos City, in the vast Inner Mongolia Autonomous Region. Established in 2006, it has a registered capital of 853.06 million yuan. The company has received various honors, including “Model Enterprise of the Autonomous Region,” “Model Enterprise in Ordos City’s Quality Month Campaign,” “Ordos City May 1st Labor Award,” and “Unit with Harmonious Labor Relations.”

Shaanxi Changqing Energy Chemical Co., Ltd. has a methanol production facility with an annual capacity of 600,000 tons. Using coal as the raw material, GE coal slurry gasification is employed, followed by a sulfur-resistant wide-temperature shift reaction in the first stage and Lindlar low-temperature methanol washing for desulfurization/descarbonization. After compression, the mixture is fed into an IMC methanol synthesis tower to produce crude methanol (using the Cassali methanol synthesis technology). The crude methanol is then refined through triple-column distillation to yield pure methanol product. The thermal power units in the auxiliary utility systems include three high-temperature and high-pressure coal powder boilers with a capacity of 180 t/h, operating at 9.8 MPa and 540°C, as well as two 12 MW condensing waste heat recovery generators. The exhaust gas from the thermoelectric unit is treated using ammonia-based desulfurization, SCR denitration, bag filter dust removal, and wet electrostatic precipitator technology.

Anhui Huayi Chemical uses multi-nozzle opposed water-coal slurry gasification for its 600,000-ton methanol production, along with Cassali IMC water-cooled plate methanol synthesis towers, which were put into operation in 2012. 3 gasification furnaces, with a gasification pressure of 6.5 MPa and a diameter of Φ3400 mm; they operate in a 2-operational-1-backup configuration during normal operation. According to Anhui Huayi Chemical’s presentation at the 6th International Symposium on the Promotion and Application of Multi-nozzle Opposed Gasification Technology, since its commissioning, the facility has undergone various improvements such as ammonia recovery, optimization of the ash water system, modification of the wash tower trays and mixers, as well as optimization of interlocks. As a result, the gasifier has been able to operate stably over long periods of time, with regular maintenance cycles of 90 days. All energy consumption and specific consumption metrics related to the gasifier meet the required standards, and safety and environmental aspects are under proper control. The device is currently operating well.

Nitrogen Fertilizer and Methanol 0706 08:11 According to Jinmei Group, Henan Jinmei Tianqing Coal Chemical Co., Ltd. has actively engaged in technical exchanges regarding the operation and maintenance of gasification furnaces. In March 2018, the company visited Henan Yima Gasification Company, Shanxi Lu’an Coal-based Synthetic Oil Co., Ltd., Shanxi Tianji Coal Chemical Group Co., Ltd., and Zhengzhou Machinery Research Institute for inspections and exchanges, aiming to draw on the strengths of various parties to ensure the long-term stable operation of the gasification furnaces. During the major maintenance of Unit 4 gasifier this year, in response to the severe wear of the large gears inside the furnace, a right-handed scraper was replaced with a left-handed one. By working together with the electrical and instrumentation department, the operation signal was adjusted from counterclockwise to clockwise direction, thereby extending the service life of the large gears. At present, the furnace is operating well, with normal performance ； For Boilers 1#, 3#, and 4#, the upper and lower valves of the ash lock opened excessively, resulting in the forced shutdown of the gasification furnace. During the major maintenance of these boilers, drawing on Tianji Company’s maintenance experience, the angles of the outer rocker arms of the upper and lower valves of the ash lock as well as the lower valve of the coal lock were adjusted to ensure that the valves could open and close properly ； In the case of the DV3 valve used in the gasification furnace’s ash locking system, the presence of many slag particles in the ash filling water results in a shorter service life for this valve, leading to malfunctions that affect the proper discharge of ash from the furnace. By adding another gate valve in front of the DV3 valve, its service life is extended to some extent, thereby preventing issues arising from prolonged lack of ash discharge due to high-load operation of the furnace. Unit 1# gasifier underwent a comprehensive system inspection in 2018; it was put into operation on April 27 and integrated into the production system. As of July 4, it had been operating safely for 66 consecutive days, breaking the previous best operating record for Unit 1# gasifier. On the same day, the 5# gasifier achieved a continuous safe operation period of over 100 days, while the 6# gasifier maintained continuous safe operation for 141 days. The goal set by the gasification task force at the beginning of the year – that two gasification units would operate safely for more than 100 days in a row – was achieved ahead of schedule. Following the major system overhaul, the second-phase unit was shut down from May 10 to June 22; the gasifier operated stably, with an average oxygen load of 42,138 m3/h over those 43 days, thereby achieving high and stable production levels. Jinmei Tianqing produces 180,000 tons of synthetic ammonia, 300,000 tons of urea, and 300 million cubic meters of natural gas using the Lurgi coal gasification under pressure, low-temperature methanol washing, liquid nitrogen washing, Cassali low-pressure ammonia synthesis, and CO2 stripping processes. Put into operation in 2015.

Anyang Zhongying Fertilizer Co., Ltd. was established in November 2010 with a total investment of 3.2 billion yuan; it is a key fertilizer production project in Henan Province. The project utilizes some of the world’s most advanced technologies in its processes, including coal-water slurry gasification technology, Cassali synthesis technology and equipment from Switzerland, as well as carbon dioxide stripping processes. It is the first fertilizer production facility in Henan Province and also has the largest single-unit production capacity. By 2015, it was capable of producing 1 million tons of urea per year, generating an annual output value of 1.8 billion yuan and profits and taxes amounting to 450 million yuan. Enterprises have the capability to independently organize chemical production and operations, promote the application of new technologies, develop new products, design manufacturing processes, and address various major issues that arise in chemical production. Through decades of practice, a large number of experienced professionals in operations, management, technology, and sales have been developed. The company has over 1,000 employees, including more than 400 technical professionals of various types.

Introduction to Yankuang Xinjiang Coal Chemical Co., Ltd. Original: Yankxinhua Yankxinhua February 8 Basic Information Yankuang Xinjiang Coal Chemical Co., Ltd. is a wholly-owned subsidiary of Yankuang Xinjiang Energy and Chemical Co., Ltd., and was established on April 13, 2009. The company’s 600,000-ton per year alcohol-ammonia co-production project has seen a total investment of 5.2 billion yuan; it covers an area of 1,050 mu and includes facilities such as air separation units, gasification units, purification systems, methanol production units, ammonia synthesis units, urea production units, as well as systems for storing and transporting raw materials, ammonia recovery systems, cryogenic stations, and other supporting utility systems. Planned and designed in 2009, construction began in full in June 2010, and it was completed and put into trial operation in October 2012. The capacity is 520,000 tons of urea and 300,000 tons of methanol per year, with by-products of 26,000 tons of sulfuric acid and 25,000 tons of liquid argon. In terms of technology and processes, the project makes full use of the technological innovation platforms owned by Yankuang Group, such as the **Key Laboratory for Coal Liquefaction and Coal Chemicals** and the **Engineering Center for Pressurized Gasification of Coal Slurry and Coal Chemicals**. It incorporates three **\"863\" project achievements**, 7 technologies that have won various awards, as well as technologies that have received provincial (ministerial) level science and technology advancement awards; in addition, 5 world-class processes are applied in the facility. This reflects a first-class integration of modern coal chemical technologies. Approximately 500 million yuan was invested in building comprehensive pollution control and emergency response facilities, and the project passed the environmental protection inspection upon completion – making it the first coal chemical enterprise in Xinjiang to achieve such approval. It mainly includes units such as air separation, gasification, purification, methanol production, ammonia synthesis, urea production, as well as systems for raw material storage and transportation, ammonia recovery, refrigeration stations, and related utility systems. It has the following characteristics: (1) Gasification: The group utilizes the achievements of the “863” program; Yankuang Group owns independent intellectual property rights for its multi-nozzle water-coal slurry pressurized gasification technology. (2) Transformation: The medium-string low transformation process is adopted. (3) Reformate purification: Utilizes domestic patented low-temperature methanol washing technology. (4) Syngas purification: An advanced liquid nitrogen washing process is employed. (5) Syngas compressor: A centrifugal compression unit driven by a fully condensing steam turbine is used. (6) Ammonia synthesis: Utilizes the internationally advanced Cassali synthesis technology. (7) Air separation: An internationally advanced Linde oxygen production unit (80,000 standard cubic meters per hour) is used; this unit is the largest of its kind in China’s chemical industry to date. (8) Urea plant: Utilizes an advanced carbon dioxide stripping process. (9) Sulfur recovery utilizes the Danish Topsoe WSA wet acid production technology. (10) All production control is automatically optimized by DCS and ESD.