Let’s talk about the innovation in nitrogen fertilizer methanol

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Let’s talk about innovations in nitrogen fertilizer and methanol production: http://www.chemcp.com, July 22, 2016, China Chemical Products Network. On July 6, at the 2016 China Nitrogen Fertilizer and Methanol Technology Conference held in Taiyuan, Shanxi, industry professionals gathered to discuss measures for innovative development in this sector, as well as the key areas and directions for technological innovation. The goal was to address the issues related to the low level of scientific and technical expertise in the industry, weak innovation capabilities, and the reliance on resources and capital investment to expand production. 　　The core problems lie in outdated equipment and a lack of funding for innovation. Gu Zongqin, president of the China Nitrogen Fertilizer Industry Association, said in his speech at the meeting that the issues facing the nitrogen fertilizer and methanol industry—being large in scale but not strong in performance—are due to factors such as outdated equipment, a shortage of talent, and insufficient funding. To enhance innovation capabilities, it is first necessary to accurately understand these problems. 　　First, the technology of some facilities is outdated, resulting in significant issues with the emission of waste gases, liquids, and solids. It was pointed out at the meeting that the technical level of some existing facilities in our country remains relatively backward, which is reflected in three main aspects: first, the scale of enterprises is relatively small, making it difficult to achieve economies of scale. For example, there are 226 enterprises with an ammonia synthesis capacity of 300,000 tons per year or less, accounting for 68.3% of the total number of enterprises, and their combined capacity constitutes 35.4% of the total capacity ； There are 267 enterprises with a methanol production capacity of less than 300,000 tons per year, accounting for 76% of the total number of enterprises; their combined production capacity is 23.41 million tons per year, representing 31.4% of the total production capacity. Second, some devices have outdated technology, resulting in high energy consumption and significant pollution. About one-third of small and medium-sized ammonia synthesis plants still use the semi-water gas-ammonia aqueous phase desulfurization and copper washing processes, with the ammonia synthesis pressure remaining at around 30 MPa ； Two-thirds of small and medium-sized urea plants have only desorption units, without hydrolysis units ； The dust emissions from most urea granulation towers exceed the specified limits. Thirdly, some production facilities lack appropriate technologies for pollutant treatment or have little willingness to carry out such treatment, resulting in arbitrary discharge of pollutants; for example, ammonia, phenol, and cyanide generated during the aeration and cooling process of gas washing cooling water are discharged arbitrarily ； Excessive emissions of sulfur dioxide and nitrogen oxides in the flue gas discharged from the waste heat recovery unit for blowdown gas ； Volatile emissions of organic substances such as methanol and propylene carbonate during the regeneration of the decarburization solvent in the wet decarburization process ； Issues such as excessive emissions of hydrogen sulfide in the released carbon dioxide gas. 　　Second, the innovation capacity is weak, and there is a lack of driving force for development. Industry experts analyze that the main reasons for the weak innovation capacity in the nitrogen fertilizer and methanol industries are a shortage of innovative talent and insufficient investment in innovation. There are few technical leaders across the industry; only 16 **-level technology centers (or sub-centers) exist, and most companies do not have dedicated R&D institutions, with limited investment in R&D efforts. Key technologies and equipment still rely on imports, such as large-scale methanol synthesis, stripping process for urea production, syngas compressors, and carbon dioxide compressors; the process of local production is progressing slowly. 　　Third, the industry suffers from low efficiency, and there is a lack of funding for innovation. Gu Zongqin said that the main reasons for the low profitability in the nitrogen fertilizer and methanol industries are, first, an unreasonable structure of raw materials and energy sources, which results in high production costs. Approximately 60% of the capacity for producing ammonia and urea is constrained by high raw material prices. The abolition of preferential electricity rates has made it difficult for small and medium-sized enterprises that rely on purchased electricity as their primary energy source to operate ； Second, there is an overcapacity in the production of ammonia, urea, and methanol, resulting in low market prices for a long time ； Third, most enterprises have simple product structures, short product chains, and weak market resilience. It is precisely because the nitrogen fertilizer and methanol industries are not profitable that there is little investment in innovation within these sectors, resulting in a lack of momentum for their development, which severely impacts the progress of these industries. 　　Fourth, there is a weak awareness of green development, and measures to reduce waste emissions are inadequate. Some enterprises in the nitrogen fertilizer and methanol industries lack awareness of green development; they prioritize profits over environmental protection and have a weak sense of responsibility. The participants agreed that the main reasons for the problems associated with the emission of waste substances in the nitrogen fertilizer industry are, on one hand, a lack of awareness regarding environmental protection; companies are unwilling to invest more funds in environmental safeguards, resulting in insufficient investment in this area and a perfunctory approach to environmental issues ； Another scenario is when a company performs poorly financially and is short of funds, preventing it from investing in new environmental protection facilities. As a result, such companies are unable to withstand inspections by environmental authorities and often have to shut down due to failing to meet environmental standards; in some cases, these companies even engage in illegal discharge of pollutants. 　　Look at the direction: Leverage policy advantages for transformation. Gu Zongqin pointed out that in order to improve the quality and efficiency of the nitrogen fertilizer and methanol industries, during the 13th Five-Year Plan period, the entire industry needs to focus on the following areas in terms of technological innovation. 　　First, raise the standard level and force the elimination of outdated production capacity. Formulate and revise limits for resource and energy consumption, as well as standards for pollutant emissions that are appropriate to China’s national conditions; use these standards to drive improvements in the production standards of various industries, and enforce the phasing out of outdated production capacities that fail to meet environmental and energy efficiency requirements. In 2015, commissioned by the National Technical Committee for Energy Foundation and Management Standardization and the China Petroleum and Chemical Industry Federation, 6 energy consumption limit standards for 4 products (synthetic ammonia, urea, methanol, and ammonium bicarbonate), with the China Nitrogen Fertilizer Industry Association as the main drafting entity, were issued. Entrusted by relevant authorities, the China Nitrogen Fertilizer Industry Association is organizing the formulation of the “Water Consumption Quotas” for ammonia, urea, and methanol products, as well as the “Water-Saving Enterprises – Nitrogen Fertilizers” standard and the “Emission Standards for Air Pollutants in the Chemical Fertilizer Industry”. These standards will provide a basis for **encouraging advanced technologies and phasing out backward production capacities that are energy-intensive and polluting**. 　　Second, establish green factories to promote green production. The Outline of the 13th Five-Year Plan for National Economic and Social Development calls for the promotion of green production and lifestyle patterns, while Made in China 2025 advocates for the establishment of green factories. The nitrogen fertilizer and methanol industries should, in accordance with the principles of technical feasibility, economic rationality, and environmental and social sustainability, adopt advanced and appropriate technologies to carry out the transformation of traditional industries. 　　——Carry out proper technical upgrades for the relocation of hazardous chemicals industries and their transfer from urban areas to industrial parks. The Ministry of Industry and Information Technology has included projects related to the relocation and transformation of enterprises that produce hazardous chemicals within the scope of support provided by **special construction funds, and has formulated a work plan for promoting the relocation and transformation of such enterprises in areas with high population density in cities. By 2020, all high-risk hazardous chemical manufacturing enterprises located in densely populated urban areas were required to begin relocation and renovation; in principle, they were to be shut down by 2025, with all such relocation and renovation projects taking place in industrial parks equipped with comprehensive safety and environmental protection facilities. The relocation and renovation of hazardous chemicals enterprises is not merely a simple reconstruction in another location; during the relocation, it is necessary to optimize the structure of raw materials and energy sources. Through informatization, automation, and intelligent upgrades, the inherent safety level of these enterprises can be improved, enabling product adjustments, technological upgrades, and enhanced efficiency. 　　——Carry out systematic optimization and energy-saving and emission-reduction technological upgrades. Vigorously promote technologies such as system optimization, hierarchical use of energy, and recycling to implement energy-saving reforms; in accordance with the requirements of the Action Plan for Air Pollution Control and the Action Plan for Water Pollution Control, adopt clean production processes, water conservation and advanced treatment and reuse of wastewater, as well as waste gas treatment and comprehensive utilization to carry out clean production upgrades, thereby reducing emissions of pollutants such as sulfur dioxide, nitrogen oxides, smoke (dust), and ammonia nitrogen in the nitrogen fertilizer and methanol industries. 　　——Implement energy-saving upgrades to general-purpose equipment systems. In accordance with the policy requirements set out by the Ministry of Industry and Information Technology and the **Development and Reform Commission, such as the \"List of High-Energy-Consuming Mechanical and Electrical Equipment (Products) to Be Phased Out,\" the \"Guidelines for Industrial Structure Adjustment,\" the \"Plan for Improving Motor Energy Efficiency,\" the \"Plan for Improving the Energy Efficiency of Distribution Transformers,\" and the \"Implementation Plan for Comprehensive Energy-Saving and Environmental Protection Measures for Coal-Fired Boilers,\" high-energy-consuming motors, distribution transformers, and coal-fired industrial boilers used in the nitrogen fertilizer and methanol industries shall be phased out. 　　——Vigorously carry out intelligent transformation projects. By leveraging next-generation information technologies such as the industrial Internet, the Internet of Things, cloud computing, and big data, promote the deep integration of information technology in the nitrogen fertilizer and methanol industries. Establish a collaborative resource management platform for these industries to achieve intelligent optimization in production, operations, management, and decision-making. 　　——Optimize and adjust the raw material structure and power structure; enterprises with the necessary resources should select appropriate advanced gasification technologies to transform their raw material processing routes, based on the availability of raw materials ； In accordance with the latest requirements of the \"Cogeneration Management Regulations,\" a transformation of the power structure is carried out that takes into account the actual conditions of the enterprise while also meeting **policy requirements**, in order to reduce production costs and enhance the enterprise’s viability. 　　Third, promote industry innovation to enhance competitiveness. The nitrogen fertilizer and methanol industries should strengthen the concept of innovation-driven development, strive to change the situation in which major key technologies rely mainly on imports, and accelerate the narrowing of the technological gap between domestic and international levels. It is necessary to establish a technology innovation system centered on enterprises, market-oriented, and integrating industry, academia, and research. A number of high-level enterprise technology centers should be built, and a group of innovative leading enterprises with international competitiveness should be fostered and strengthened. Strengthen the development of a team of innovative talents, cultivate such a group with innovative vitality, strive to achieve major breakthroughs in key technologies, and innovatively develop a range of new technologies and equipment that are at the international and domestic advanced level and meet the needs of industry development. 　　Key points: Energy conservation and emission reduction reforms must be carried out effectively. At the meeting, Gu Zongqin pointed out that the entire industry must earnestly implement the requirements set forth in the “13th Five-Year Plan for National Economic and Social Development” and “Made in China 2025”. It is necessary to carry out green and intelligent transformations in the nitrogen fertilizer and methanol industries. Moving forward, these industries should focus on four main areas: developing a range of key production technologies that reach domestic and international advanced levels; vigorously promoting energy conservation and emission reduction technological upgrades; striving to adjust their product structures; and actively engaging in industry benchmarking and excellence evaluation efforts. 　　Gu Zongqin emphasized that the main focus of technological innovation in the nitrogen fertilizer and methanol industries is, first and foremost, the development of a set of key production technologies that reach advanced levels both domestically and internationally. Tackle a number of core technologies that rely on imports. 　　Secondly, the entire industry should vigorously promote technological upgrades for energy conservation and emission reduction. The first is the technical transformation for system energy and power conservation. Upgrade the energy efficiency of the plant by employing technologies such as isothermal conversion technology, large-scale low-pressure synthesis technology, high-efficiency catalysts, pre-reduction catalysts, steam stripping processes for urea production, JX energy-saving urea, and high-efficiency equipment ； Strengthen system optimization, renovation, and management improvements to enhance mass and heat transfer efficiency and reduce the volume of fluid that needs to be transported ； Use power-saving equipment to improve electricity efficiency ； Accelerate the transformation of the power structure to reduce external power consumption ； Enhance the hierarchical utilization of energy and the comprehensive use of waste heat and pressure to reduce the overall energy consumption of the system. The second is the technological transformation for ultra-low wastewater discharge. Continue to implement the technological transformation aimed at “zero discharge of wastewater from nitrogen fertilizer production”. Adopt clean production processes to reduce pollutant generation at the source. Make comprehensive use of wastewater with high ammonia-nitrogen and COD contents. Promote the application of technologies such as ultra-low discharge of circulating water, reclamation of reclaimed water, fractional salt crystallization, and novel coal gasification for the synergistic treatment of high-concentration organic wastewater and waste solids to produce syngas. These measures will help reduce emissions of ammonia-nitrogen, total nitrogen, COD, and other pollutants. Third is the technological transformation for reducing atmospheric pollutants. Special emphasis is placed on implementing clean production reforms for process exhaust gases, boiler flue gases, and granulation exhaust gases. Improve the technical level of comprehensive utilization of waste gases, wastes, and wastewater; recover LNG from by-produced methane, and produce sulfuric acid from acidic gases ； Upgrade the waste heat recovery systems for blast air; replace small-scale medium- and low-pressure blast air waste heat recovery units with large-scale high- and sub-high-pressure boilers. Upgrade coal-fired boilers as well, and advance the renovation of dust washing and recovery systems in urea granulation units. 　　Once again, companies should strive to adjust their product structure. With the goal of improving nitrogen fertilizer utilization, efforts are being made to significantly adjust the structure of fertilizer products. Deepen the implementation of the \"Action Plan for Zero Growth in Fertilizer Use by 2020,\" with the goal of achieving a fertilizer utilization rate of over 40% for major crops by that year. Priority should be given to the development of a range of new fertilizer varieties that can be produced on a large scale for use in field crops, including nitrogen fertilizers with enhanced efficacy, urea-ammonium nitrate solutions, nitro-compound fertilizers, water-soluble fertilizers, high-efficiency liquid fertilizers, ammonium calcium nitrate, and phosphoric acid fertilizers. 　　Aiming to improve corporate efficiency, efforts are being made to adjust the structure of chemical products. Guided by market demands and with coal gasification as the core, using carbon monoxide, hydrogen, synthetic ammonia, nitric acid, urea, methanol, and other substances as primary raw materials, the goal is to develop chemical products that make use of suitable raw materials, employ advanced technologies, and suit regional characteristics, as well as high-value-added downstream products, thereby achieving differentiated development. 　　Fourth, carry out extensive industry benchmarking and excellence evaluation activities. Continue to carry out the identification of benchmark enterprises that lead in energy efficiency for ammonia and methanol production, in order to establish benchmarks for energy conservation ； Carry out the recommendation and selection of leaders in water efficiency for ammonia synthesis and methanol production products, in order to establish benchmarks for water conservation ； Establish the “Technical Progress Award for the Fertilizer and Methanol Industries” to encourage innovation, promote the adoption of innovative achievements, recognize technical innovations in a timely manner, and accelerate the industrialization of such technological advancements ； Conduct evaluations for advanced units in energy conservation and emission reduction, to promote the circular and sustainable development of the nitrogen fertilizer and methanol industries during the 13th Five-Year Plan period ； Conduct evaluations of advanced and applicable technologies for energy conservation and emission reduction to promote the healthy development of the nitrogen fertilizer and methanol industries during the 13th Five-Year Plan period. (Jiang Xiaomao)