【Ten Years of Rapid Development in Chemical Equipment】1929–2024: China’s first syngas production plant using pyrolytic tar as raw material operated continuously for 315 days

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Safety first. Prevention first – let’s give praise and support to the achievements made in China’s chemical engineering technology and equipment. **********************【Ten Years of Great Development in Chemical Engineering Equipment】A continuously updated summary post is available; feel free to join the discussions at https://bbs.hcbbs.com/thread-3576046-1-1.html (Source: Haichuan Chemical Engineering Forum) ***************** As of July 1st, the syngas unit in Department 2 of Daqing Petrochemical’s chemical operations has been in operation for 315 consecutive days, breaking the record for continuous operation. This facility is the first in China to use pyrolyzed tar as a raw material for producing syngas, and its stable operation ensures the efficiency of the butyl octanol production plant. At present, Daqing Petrochemical produces around 233 tons of butanol and about 385 tons of octanol per day, generating a daily profit of over 1.4 million yuan.   Daqing Petrochemical actively reinforces the philosophy that \"stability leads to significant benefits,\" focusing strenuously on production control and equipment maintenance. It ensures the long-term operation of its facilities through precise production practices, and relies on thorough and rigorous control measures to support the high-quality development of the enterprise.   The syngas plant supplies raw materials for the butyl octanol plant. To ensure the stable high-load production of high-performance products, Daqing Petrochemical has made significant progress in addressing the key factors that affect the long-term operation of the syngas plant, namely the gasifier burners and the feedstock tar.   The process burner Z-1201 is the core equipment of the gasification furnace, providing a channel for the reaction materials in the furnace. To extend the service life of the burners, Daqing Petrochemical established a technical task force that monitors and analyzes data in real time during the operation of the burners, and holds special meetings to summarize and analyze the results of the inspections as well as the operating conditions. At the same time, communication was held with the manufacturer to carry out an “upgrade” of the material used in the old burners. Technicians control and adjust the parameter ranges, strengthen regular inspections and maintenance, and promptly identify and address potential issues.   To address the issue of hydraulic oil degrading easily due to high temperatures in the crude oil pump, technicians measure the temperature and vibration of both the crude oil pump and the process water pump on a daily basis, so as to detect equipment failures promptly. Since the onset of summer, the temperature at the cylinder outlet has increased; as a result, management has developed emergency plans to address this issue, and has intensified monitoring of the flow rate and pressure of the circulating water.   To extend the service life of the process burners in high-temperature, high-pressure, and highly corrosive environments, Daqing Petrochemical applies a supersonic flame carbon-based high-temperature thermal barrier material to the surface of the burner heads. This material can effectively reduce the rate of damage to the material at the head of the process burner.   During the efforts to address the issue related to tar, the frequency of analyzing the tar storage tanks in the combined transfer unit area of Ethylene Unit 1 was increased, so that Chemical Operations Unit 2 could keep track of changes in the tar composition and make timely adjustments to the various parameters of the burners. At the same time, increase the frequency of laboratory analysis for the tar receiving tank, and make timely adjustments based on the analysis results.   Yidu Science adjusts the ratio of light and heavy fuel oil extraction, optimizes the operation of the viscosity reduction tower, strictly monitors the opening degree of the emergency cooling water valve on the side of the tar product cooler, conducts sampling and testing analyses on a daily basis, and makes comprehensive assessments of the tar viscosity indicators to ensure that the product quality compliance rate reaches 100%.   As China’s first facility to produce syngas using pyrolytic tar as raw material, and without any existing experience to draw on, Daqing Petrochemical has delivered an excellent performance in ensuring the long-term operation of domestically produced burners by addressing operational issues, controlling product quality and raw materials, and identifying potential risks throughout the process. Through relentless efforts, the service life of the burner has been gradually increased from the initial 4 hours to the current 315 days. Currently, the device is operating smoothly, with its long-term operation records being continuously broken.