Anchoring the power point and sprinting for high quality - a record of technical breakthroughs in the coking unit of Fushun Petrochemical Co., Ltd.

The 2.
4 million t/a coking unit of Fushun Petrochemical Company anchored the two key points of safety production and cost reduction and efficiency improvement, and solved the problems encountered in high-quality development through technological innovation, and achieved remarkable results
.
During the overhaul period last year, the workshop implemented a series of key projects, which significantly improved the thermal efficiency and stable operation rate of the heating furnace, and achieved fruitful economic benefits

New coatings improve furnace thermal efficiency

The heating furnace is the key equipment of the coking unit.
It is responsible for heating the residual oil to the 500°C required for the coking reaction.
It consumes a large amount of fuel every year and is also a large energy consumer in the workshop
.
The workshop focused on the key points of reducing consumption, and researched technological transformation measures to minimize the energy consumption of the heating furnace

The furnace body of the delayed coking unit consists of 3 radiation chambers, 3 convection chambers and a chimney
.
In order to achieve the purpose of saving energy and reducing consumption, during the overhaul in 2021, the coking workshop adopts the energy-saving technology of ceramic coating, and sprays high-temperature anti-radiation paint on the lining surface of the heating furnace F101A and F101B radiation chamber, and sprays the surface of the furnace tube in the radiation chamber to strengthen the absorption of nano-coating , so as to achieve the effect of improving the heat transfer per unit area of ​​the radiant furnace tube wall, reducing the heat dissipation loss and improving the thermal efficiency

The energy saving effect is obvious after the transformation of the radiation chamber lining and furnace tube with high temperature radiation coating
.
After more than half a year of practical verification, the heat transfer effect of the radiant hearth furnace tube and the inner wall of the lining and the heat transfer efficiency of the radiant chamber have been improved, which has further improved the overall thermal efficiency of the heating furnace, reduced the heat dissipation loss of the furnace wall, and reduced flue gas emissions.

　　It is estimated that after the heating furnace is sprayed, the temperature of the tube wall will drop by about 5℃, the temperature of the furnace will drop by about 6℃~7℃, the temperature of the furnace surface will decrease by 1℃~2℃ after spraying, and the fuel consumption will decrease by 0.
07%, which is less than the same period of the previous year.
461 kg/day, saving fuel consumption of 117,500 yuan per year
.

　　Reduce consumption and save production costs

　　The cadres and employees of the coking workshop, in line with the concept of "what you save is what you earn", have carried out the work of saving consumption and reducing consumption based on the actual situation, and have achieved remarkable results
.

　　The cost of the lye used in the liquefied gas desulfurization unit of the double-deletion unit in this workshop remains high, and the waste caustic generated in the production process also increases the hidden danger of environmental protection
.
After the overhaul started in 2021, the workshop, in accordance with the company's requirements for quality improvement and efficiency improvement, after a comprehensive investigation and index comparison, the whole system was switched to a newly configured catalyst lye, which has achieved remarkable energy saving and consumption reduction effects

　　Before the overhaul of the device in 2021, the coking workshop will replace about 10 tons of lye every month on average, and correspondingly generate 10 tons of waste alkali
.
After using the newly configured catalyst lye, the workshop strengthened management and supervision, optimized the operation, and achieved the results that the newly configured lye has a higher concentration, better regeneration effect, and a significant reduction in the frequency of lye replacement

　　During the production process of the catalyst, due to the coking and coke powder deposition at the top of the bed, the bed pressure difference increases, which affects the normal operation
.
Since the refilling of the diene saturation reactor catalyst in March 2019, the workshop has strengthened management and inspection and supervision, strengthened the inspection and maintenance of key equipment such as new hydrogen and circulating hydrogen compressors, strictly controlled the quality of coking gasoline, and eliminated hydrogen Coke powder deposition on the top of the reactor caused by fluctuations, large fluctuations in circulating hydrogen amount and feed amount, and strict control of various parameters such as raw material properties and reaction temperature, so that the service life of the catalyst of the diene saturation reactor in the gasoline hydrogenation unit can be extended by 13 Month, saving 396,500 yuan in replacement costs

　　Innovation and upgrade optimization control system

　　As an important control core of a coking unit, DCS is related to the normal operation and adjustment of the unit and the emergency treatment of abnormal chains, and plays a vital role in ensuring the safe production of the unit
.

　　Since the coking unit was completed and put into operation in 2009, the Siemens control system has been adopted, and the control loop is relatively cumbersome
.
In order to realize the localization of DCS and ensure the long-term safe production of the device, the workshop will carry out localization transformation of the DCS during the shutdown and maintenance of the device in 2021, and the original Siemens operating system will be changed to Zhejiang Zhongkong operating system

　　This transformation abandoned the complicated and cumbersome traditional method of Siemens, and adopted a more concise and optimized central control system, which not only reduced unnecessary control loops, but also made the coking unit automatic control rate reach more than 98%, an increase of 3 percentage points compared with the previous one.
The improvement of the level also reduces the work intensity of the operator, so that the workshop is equipped with advanced technology, excellent production equipment, modern control system and management system, which provides a strong guarantee for the safe and stable operation of the device
.