Dongguang Chemical: Green development helps the company ‘renew itself’”

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Dongguang Chemical: Green development helps the company ‘renew itself’ Author/Source: Sinochem News Network Date: 2023-06-09 Clicks: 32 Hebei Dongguang Chemical Co., Ltd. (hereinafter referred to as “Dongguang Chemical”) is a urea production enterprise that was established in 1970 and uses anthracite coal as raw material. On the path toward sustainable development, Dongguang Chemical integrates the new development concepts of \"innovation, coordination, sustainability, openness, and sharing\" into its production and management processes. It pursues a green development strategy focused on energy savings and reduced emissions, works to create intelligent and information-driven factories, and strives to build a new version of Dongguang Chemical that is environmentally friendly. This approach aims to foster a harmonious coexistence between humans and nature, enabling traditional coal chemical plants to gain new momentum through sustainable development. 　　Wang Zhihe, chairman of Dongguang Chemical, said that in recent years the company has implemented over 60 energy-saving and environmental protection projects. With an average annual investment of more than 100 million yuan in green development, it focuses on energy conservation, waste reduction, circular development, comprehensive utilization, and clean production. The company actively pursues technological innovation and takes measures to reduce emissions and save energy, striving to achieve harmless raw materials, low-carbon energy use, resource recycling, clean production processes, and green products, thereby establishing itself as a **-level green factory. Over the years, its consistent efforts in energy conservation and environmental protection have helped Dongguang Chemical, a traditional urea producer, thrive; in 2022 it achieved sales revenue of 4 billion yuan and paid 150 million yuan in taxes. From January to April this year, the company produced a total of 406,000 tons of urea, an increase of 13% compared to the previous year. It generated sales revenue of 1.5 billion yuan, up 7% on a year-on-year basis, and paid 40 million yuan in taxes, representing a 16% increase. While achieving increased profitability, Dongguang Chemical shares the benefits of its development with its employees. At the beginning of 2023, salary increases were implemented; building on the revenue generated in 2022, the company raised each employee’s monthly salary by no less than 8%, ensuring that employees can truly benefit from the company’s growth. 　　Energy conservation and consumption reduction drive green development. Since 2022, the company has focused its energy-saving efforts on utility systems such as water, steam, and electricity; through targeted energy-saving measures, it has continuously reduced energy consumption per unit of product produced, thereby improving energy efficiency. 　　Wang Zhihe said that, on the basis of having already carried out upgrades to the concentrated wastewater recovery systems and the reclaimed water reuse systems, Dongguang Chemical is once again expanding these reclaimed water reuse systems this year by adding new pre-treatment units for reclaimed water, in order to increase water recovery effectively ； New hierarchical treatment and reuse of circulating water wastewater across the entire plant have been introduced to reduce discharge and improve the quality of circulating water ； The wastewater treatment facility was upgraded to increase the amount of water that can be recovered. 　　Dongguang Chemical carries out comprehensive management and overall optimization of steam generation and consumption across the entire plant. Based on the principles of \"tiered utilization and distributed utilization,\" it formulates a planning scheme for the steam system layout, optimizes it appropriately, and realigns steam of different qualities to achieve tiered recycling of steam ； Multiple measures were taken for the steam generation unit to increase steam output; various coal combinations were tried out for mixed combustion, boiler optimizations were carried out as well as modifications to the soot blowing system, in order to improve the quality and temperature of the steam ； An analysis was conducted of the steam-using units; measures such as using waste heat in place of steam were adopted to reduce unnecessary steam consumption. In winter, heating the water from the Yangtze River was done using urea waste heat instead of steam. Advanced equipment and technologies were employed to carry out energy-saving upgrades in the steam generation and urea production processes. This approach helps to reduce steam usage in a rational manner, while also making full use of the thermal energy from steam, thereby achieving energy savings in various ways. 　　Wang Zhihe said that in order to further improve the level of ammonia synthesis production, the company invested 50 million yuan in 2022 to carry out energy-saving upgrades to the 600,000-ton urea production facility. Additional equipment such as ammonia synthesis towers, waste heat boilers, and preheaters were installed on top of the existing synthesis units, enabling parallel operation with these existing ammonia synthesis towers and their associated auxiliary equipment. This approach helps to reduce the operating pressure and system resistance in the synthesis process, enhances safety, and lowers energy consumption. After the project is put into operation, it can save 25,000 tons of standard coal per year. 　　Entering 2023, Dongguang Chemical has made significant efforts to improve quality and efficiency as well as to strengthen its foundational capabilities. It carried out various renovation projects aimed at optimizing existing production facilities and reducing energy consumption, including energy-saving upgrades to the gas generation furnaces and fans, modifications to the steam supply system, energy-saving reforms for urea production, and improvements to the 600,000-ton ammonia synthesis plant. These efforts have yielded good results; in the first quarter of this year, the company’s coal consumption per ton of ammonia produced decreased by 16 kilograms compared to the previous year. 　　Dongguang Chemical makes use of digital technologies to drive digital and intelligent management in its facilities. The company invested 3 million yuan in developing a safety information platform that enables real-time tracking of inspectors using Bluetooth+UWB technology, allowing for the display of their locations within the production areas, as well as access to their information and activity records. This approach helps advance the management of hazardous chemical production from a mechanical-based system to a more sophisticated, intelligent system that meets higher standards in terms of safety and environmental protection ； An electronic fence is established, with functions such as overpopulation alerts and timeout alerts for stationary objects within the area, and it is integrated with nearby video surveillance systems ； Intelligent inspection is utilized to plan comprehensive inspections for the inspection routes and key equipment, thereby continuously reducing blind spots in inspections. Data comparisons of the inspection results are carried out to identify any abnormalities, which are then analyzed and assessed promptly to improve work quality and efficiency. The company has also invested over one million yuan in implementing an intelligent digital system based on a framework of supply chain management ERP systems, financial SAP systems, and unattended logistics management systems. It will further improve systems such as the intelligent factory MES system and the organizational support management BI system, in order to achieve deep interaction among equipment, materials, personnel, and processes, thereby advancing the development of automated, unmanned, digital, and intelligent factories. 　　Promote clean production and establish a low-carbon circular development system. The \"Guiding Opinions of the State Council on Accelerating the Establishment of a Green, Low-Carbon, Circular Economic System\" state that efforts should focus on energy conservation and emission reduction, clean production, and clean energy, with breakthroughs made in these areas first; clean production should be implemented on a comprehensive basis to ensure a continuous improvement in its standards. In recent years, Dongguang Chemical has been continuously advancing its efforts in clean production and establishing a sound system for green, low-carbon, and circular development. In 2021, Dongguang Chemical successfully passed the clean production audit. 　　Control emissions at the source and ensure clean production on site. It was the first in the industry to implement dust removal, desulfurization, and denitrification for circulating fluidized bed boilers and boilers that burn mixed waste materials; currently, its emission levels consistently meet ultra-low emission standards. The company proactively invited qualified third parties to conduct a comprehensive inspection of its production processes, in order to identify and address sources of volatile organic compound emissions within those processes on its own. Since June 2020, leak detection and repair have been carried out on a quarterly basis each year, in order to control leak sources at their origin and carry out targeted repairs to the leaking points. At the same time, the company encourages workshops to conduct self-inspections for potential environmental hazards, and offers incentive programs to motivate employees to strive to become model workshops, thereby making the production process more sustainable and efficient. 　　Wang Zhihe explained that the company adheres to the principles of \"reduction, reuse, and resource utilization\" to achieve a circular production model that makes full use of intermediates, by-products, residues, and waste. 　　Dongguang Chemical utilizes advanced technology to process available resources such as hydrogen and methane through hydrogen extraction and pre-recycling processes, thereby establishing an LNG production facility with an annual capacity of 10,000 tons. It also uses industrial waste, namely fly ash, to produce concrete blocks, which increases the added value of the waste generated by the ammonia synthesis industry; this approach helps to reduce solid waste emissions by over 100,000 tons per year. Since 2013, the company has provided heat sources free of charge for the heating project in the urban area of Dongguang County. To date, the company’s industrial waste heat and residual heat have been used to heat 68 residential areas and 3 schools in the urban area, covering a heating area of 3 million square meters and benefiting over 100,000 people. During each heating season, the company can help save 50,000 tons of coal used for heating in the local community, thereby reducing emissions of carbon dioxide, sulfur dioxide, dust, and other pollutants, **improving the environment. 　　Wang Zhihe said proudly that Dongguang Chemical took a proactive approach by being the first in the industry to engage in carbon dioxide capture and recycling. The 150,000 tons per year liquid carbon dioxide recycling facility, which came online in 2011, is used to recycle the PSA decarbonization off-gases from ammonia synthesis plants. Based on calculations using data related to carbon capture, utilization, and storage, the company’s project for recovering 150,000 tons per year of liquid carbon dioxide can result in a reduction of approximately 80 million cubic meters of carbon dioxide emissions each year. This is equivalent to the carbon dioxide emitted by burning 60,000 tons of standard coal, or it is equivalent to 100,000 economy cars not being used for one year, or to planting 1.35 million trees. Based on typical standards for economic forestry, this is also equivalent to the carbon dioxide absorption capacity of 6,500 acres of forested land. 　　Implementing fixed-bed environmental protection upgrades to set a benchmark for industry standard improvements Wang Zhihe said that on Dongguang Chemical’s path toward green development, the most significant achievement and something of which the company’s employees are particularly proud is the investment of 170 million yuan in carrying out the first of its kind clean fixed-bed batch gasification ammonia synthesis upgrade project in the country. In the face of uncertainties and risks associated with project decision-making and implementation, Dongguang Chemical made outstanding efforts and demonstrated great courage, daring to explore in the unknown and moving forward with determination despite difficulties. Ultimately, the project was successfully implemented and has been operating well, achieving zero emissions of wet slag and VOCs, as well as extremely low wastewater emissions, thus setting a model for environmental protection upgrades using fixed-bed technology across the industry. This model has been widely adopted and applied throughout the sector. 　　In 2019, as environmental protection policies became increasingly strict and there were calls to phase out atmospheric-pressure fixed-bed batch gasification, Dongguang Chemical took on this historical mission. In August of that year, with the support and guidance of the China Nitrogen Fertilizer Industry Association, and in the absence of any precedents for treating the circulating water used in fixed-bed gasification at its source, the company dared to innovate and, in collaboration with its partners, developed and implemented China’s first environmental protection project for fixed-bed gasification systems, enabling the transition from direct cooling to indirect cooling of the water used for gas production, as well as ensuring the clean treatment of such water. At the same time, the gas generation section was equipped with fully enclosed vibrating screens, mist suppression systems, and automatically upgraded coal feeding and slag discharge systems, thereby achieving complete automation of the gasifier operation and enhancing its safety. 　　On November 10, 2020, the project passed the scientific and technological achievement appraisal conducted by a panel of experts organized by the Fertilizer Association, and received high recognition from the Fertilizer Association and representatives of relevant departments. In July 2021, the company’s \"Fixed-bed batch gas generation circulating water volatile pollutant control technology\" was awarded the \"Special Prize for Science and Technology\" by the China Nitrogen Fertilizer Industry Association; in September 2021, it received the \"Third Prize for Science and Technology\" from the Chinese Chemical Society. 　　Adhering to green principles to drive product improvement and upgrading Wang Zhihe explained that Dongguang Chemical focuses on green development, choosing eco-friendly vehicle urea solutions as well as green and efficient specialized compound fertilizers among its various downstream products. 　　Vehicle urea solution can reduce nitrogen oxides in diesel engine exhaust emissions to nitrogen and water, effectively decreasing air pollution emissions. In 2019, leveraging its own urea resources and advantages in utility services, the company built a project capable of producing 500,000 tons of vehicle urea per year. Among them, the first-phase project with an annual production capacity of 300,000 tons of urea solutions for use in vehicles was successfully put into operation in December of that year, achieving full production capacity and efficiency. It is applicable not only to various diesel motor vehicles equipped with SCR systems, but also to non-road mobile machinery and wheeled vehicles used for specialized construction tasks. In 2022, sales revenue from automotive urea exceeded 230 million yuan, with taxes paid amounting to 15 million yuan. 　　In 2022, the company put into operation a project capable of producing 150,000 tons per year of green, high-efficiency special compound fertilizers. The high-efficiency fertilizer produced by this project can release nutrients at different stages of crop growth, thereby reducing nutrient loss and significantly improving the efficiency of fertilizer use while also decreasing the amount of fertilizer needed – thus contributing to the goal of **reducing fertilizer use while increasing efficiency**. High-efficiency humic acid-based fertilizers not only meet the nutrient needs of crops but also help to alleviate and improve soil compaction, enhancing the crops’ ability to absorb nutrients. They have significant effects in increasing crop yields, improving the quality of agricultural products, and activating the soil. Various sulfur-based compound fertilizers with high, medium, and low nutrient levels can meet the needs of different types of soils and crops; they are \"all-purpose\" compound fertilizers that can serve agricultural needs in all aspects. 　　Remaining true to its original aspirations and striving to fulfill its mission of ensuring supply, Wang Zhihe said that Dongguang Chemical is a key enterprise in China’s fertilizer production sector responsible for ensuring a stable supply of fertilizers. Since 2022, Dongguang Chemical has remained committed to its goal of contributing to the development of the industry through the strict management of critical facilities and equipment, as well as through improved oversight of process equipment. It has made every effort to ensure the long-term, safe, stable, and efficient operation of these facilities. During the autumn fertilizer preparation period in November 2022, despite the pressures posed by the pandemic, Dongguang Chemical implemented closed-production measures, coordinated efforts between pandemic control and production activities, and arranged production schedules as well as employees’ living conditions appropriately. As a result, the company produced 1.106 million tons of urea throughout the year, exceeding the fertilizer production targets set by the Ministry of Industry and Information Technology. In January 2023, the company received a letter of appreciation from the Ministry of Industry and Information Technology, which expressed gratitude and recognition for the company’s efforts in ensuring a stable supply of fertilizers in 2022: \"Ensuring a steady supply of fertilizers is crucial for maintaining **food security. Dongguang Chemical showed great responsibility and commitment, doing everything possible to maintain and increase production levels, thereby exceeding the minimum production targets and making significant contributions to ensuring the supply of fertilizers.\" ” 　　Wang Zhihe said that in the future, Dongguang Chemical will, as always, adhere to a path of safe development, green development, high-quality development, and sustainable development. It will focus on strengthening its core business, build a solid foundation, pursue green development to enable long-term progress, and forge a distinctive path of green, efficient, and high-quality development.