en.Wedoany.com Reported - Data has come in from the production site of Zhongtai New Materials: the No. 3 gasifier recently achieved a successful one-time startup. This startup was not merely the ignition of the unit, but also a subversion of the traditional startup logic for coal chemical plants.
As the "heart" of a coal chemical plant, starting up a gasifier has always been akin to "walking a tightrope." Any deviation during the gas integration phase can, at best, cause system pressure fluctuations and, at worst, lead to a complete production line shutdown. Previously, the industry commonly used a "step-by-step relay" operation: first, the syngas was integrated into the purification system buffer, and then connected to the synthesis system in steps. While this process was stable, the entire procedure took over 10 hours, involving significant redundant waiting time.
Faced with the challenge of "three overlapping phases"—the final stage of project construction, the trial production run-in period, and the production operation transition period—Cao Xiangmin, Deputy General Manager of Zhongtai New Materials, provided the answer: abandon redundant processes and seek efficiency through precise control.
The core weapon brought forth by the technical team this time was an operational strategy called "Dual-System Synchronous Pre-adjustment, Pressure Gradient Direct Connection." They broke the mindset that syngas must be "transferred" through the purification system. By capturing three key parameters—pressure, temperature, and composition—of the gasifier and the synthesis system in real-time, they achieved dynamic coupling and precise control, directly opening a "high-speed channel" from the gasifier to the synthesis system.
This refined operational plan has completely transformed the experience for operators. Gao Zhiping, Director of the Gasification Workshop, revealed that in the past, step-by-step operations required monitoring two systems and making repeated adjustments, with constant worry about parameter fluctuations and excessive time consumption. After the implementation of the new plan, intermediate transition steps were eliminated, the syngas quality compliance rate reached 100%, truly achieving "speed increase without quality reduction," making frontline operations both less demanding and highly efficient.
From over 10 hours down to just 7 hours and 6 minutes, the startup time was shortened by a full 2 hours and 54 minutes. This figure set a new record for the shortest time since the company began trial production.
This case proves that refined management is not a slogan hung on the wall, but scientific control implemented at every pressure gauge and every temperature node. Currently, the technical backbone of Zhongtai New Materials is intensively tackling the final barriers of dynamic control of the gasifier outlet pressure and collaborative optimization with the purification system, driving production management towards a smarter, more efficient, and safer direction.
The project has a total investment of 5.991 billion yuan, adopts advanced Chinese coal chemical technology, and primarily uses raw coke oven gas, undersized coal powder, and coke breeze as raw materials to produce methanol, featuring characteristics of low energy consumption and low emissions.
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