【Haichuan’s Best Practices】Changing the power frequency of the liquid ammonia loading pump reduces ammonia emissions by 100 tons per month
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“With the inverter in operation, at least 200,000 yuan can be saved each month. ”On August 3, 2021, in front of the low-voltage distribution cabinets in the 6-kilovolt distribution room of the main transformer at the third fertilizer production unit of Ningxia Petrochemical Company, six employees from the Electrical and Instrumentation Team calculated the costs associated with improving quality and efficiency. Recently, the designed flow rates at the outlets of the two ammonia transfer pumps in the ammonia station of the three fertilizer production units were too high, resulting in insufficient filling during the loading of liquid ammonia. The returning liquid ammonia caused an increase in the temperature and pressure inside the ammonia tanks. This not only requires releasing some ammonia, but also necessitates frequent activation of the two chillers for cooling, resulting in increased power consumption. Yu Yong, the deputy director of Workshop 2 in the Electrical and Instrumentation Department, suggested adding an inverter to change the pump’s operation mode from fixed-frequency to variable-frequency operation. Technicians and employees from Shift 3 of the electrical and instrumentation department held a brainstorming session to come up with specific plans. On the one hand, apply to the Maintenance Department to arrange for a professional company to conduct a thorough inspection and repair of the frequency converters that have been unused for many years; on the other hand, expedite the completion of tasks such as preparing technical plans, removing obsolete materials, and configuring the DCS system. All the spare parts were in place, and the employees of the electrical third shift completed the wiring and debugging work between the low-voltage cabinets, frequency converter cabinets, motors, and DCS cabinets within two days. After the renovation, ammonia emissions are reduced by about 100 tons per month, resulting in savings of 200,000 yuan per month. The electrical energy consumption associated with starting the chillers and ammonia transfer pumps is reduced by about 40,000 kWh, leading to savings of 18,000 yuan in electricity costs. Not only that, but the once-used equipment has been revived through renovation.
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It falls under the category of rationalization suggestions. Many good rationalization suggestions come from front-line workers and technical personnel. Rationalization suggestions should be combined with QC projects to address bottleneck issues. Unite as one, reduce costs and improve efficiency while minimizing labor use, and achieve honors...
It’s great advice. Many suggestions related to boosting morale might seem simple or inappropriate at first, but through the measures you’ve mentioned, it’s possible to train the team, increase employees’ interest, improve their skills, and foster a corporate culture
This post was last edited by pzhmotor on 2022-5-2 at 16:11. Yes, the implementation of such activities depends on the company’s orientation and the level of attention given by its top management. It is mainly the unions and technical departments that take the lead in carrying out such work. Reasonable suggestions that yield significant benefits and can resolve production bottlenecks are more likely to result in \"golden ideas\" or \"silver ideas\", with prizes starting at tens of thousands. There are easy opportunities to gain honors and promotions. A colleague was named an outstanding employee by the group for achieving \"level 3 cooling of chilled water,\" and he is now the head of the Equipment Department. Another friend was named a national model worker for “extending the service life of smelting furnace electrodes”. Both of these guys started out as team leaders and have been to the RM Convention Hall... In domestic companies, this is called a rationalization suggestion, while lean production management is referred to as on-site improvement. The currently popular “simple automation” is also mostly bottom-up. From my experience, those on the ground are always better aware of the problems that arise at a specific location than technical staff and managers. He may not necessarily be able to come up with a perfect solution, but he can identify the problems and phenomena; once technicians get involved, there’s a chance to achieve much with little effort. The internal motivation is “reducing the workload and providing compensation and recognition,” which makes people willing to do the work. QC activities carried out through teamwork often include valuable and reasonable suggestions. Good rationalization suggestions can also be packaged as QC to earn more money. The topic of this inverter modification can also be turned into a QC project.
In fact, knowing exactly how to do it is one thing; creating an atmosphere and *habit that encourages such actions is more important