On January 11, Qilu Petrochemical Rubber Factory received exciting news. In 2010, they seized the opportunity for a strong sales of the domestic synthetic rubber market. The equipment load was steadily increased and the production capacity was “blow-out†released. The annual production of 346,600 tons of synthetic rubber, far exceeding the annual designed production capacity of 270,000 tons, the output ranked first in the country. At the same time, the company sold all its products and realized a profit of 633 million yuan.
The 270,000 tons of production capacity is not the largest in the country, but they must do everything possible to let the equipment complete more tasks. Especially in December of last year, the company's production load reached 130% of the design value.
To make the device as high as possible to increase the load, it is necessary to maintain continuous, efficient, safe and stable operation. Qilu Petrochemical Rubber Factory implements “four-in-one†equipment special protection measures for machinery, electricity, instrumentation and technology, intensive cultivation, 24 hour tracking and inspection of key equipment units, timely understanding of changes in equipment operating parameters, and eradicating equipment failures and accidents. The status avoids unplanned shutdowns and lays a good foundation for large synthetic rubber production.
In order to ensure safe and stable production, they “come out of jealousy and penaltiesâ€. In August 2010, in response to a factory-level production accident, the factory imposed penalties on related personnel, and many were fined tens of thousands of yuan. In September 2010, an employee discovered a major hidden danger in construction and immediately received a reward of 5,000 yuan. They also rewarded each month with good people who discovered potential accidents and avoided accidents. In the whole year, 715 cases of hidden troubles were eliminated, and 837 people were rewarded. The amount of reward was 69,950 yuan.
Because rubber production materials are highly viscous and easy to plug, the seven synthetic rubber post-processing production lines have become the bottleneck restricting the high-load production of the whole plant. The electromechanical integration class responsible for maintaining the operation of the production line put forward the concept of “predictive maintenanceâ€, carefully inspected the production line, discovered problems in advance, and handled the equipment in advance. The failure of the equipment was reduced by 50%, and more effective production time was obtained for the device. The degassing tower of the core equipment of the 100,000-ton/year styrene-butadiene rubber plant put into operation in June 2009 has been extended from less than one week in the initial driving period to more than 150 days, and the daily output of the plant has been increased from 240 tons to 380 tons.
In the fourth quarter of 2010, the factory carried out a special labor competition for increasing production of rubber according to the situation of high market prices for rubber. The rubber production hit a new high every month, especially in November and December of last year, creating a new record of 1000 tons of Nissan rubber. Record.
In respect of raw material supply, the plant optimized the storage of the tank farm and reconstructed the process of receiving the carbine butadiene, which increased the butadiene storage capacity from 3,000 tons to 5,500 tons, and reserved sufficient raw materials for high-load production. At the same time, we strengthened the management of product out-putting and value transfer, actively coordinated external units such as sales and transportation, and ensured that products were delivered in a timely manner.
In order to achieve efficient operation of the plant, the plant completed 14 scientific research and development projects throughout the year. After the development of the APC advanced control system for the secondary extraction plant, the fluctuation of key process parameters was significantly reduced. Through optimized operations, the butadiene yield was improved. Increase 0.54%, energy consumption decreased by 1.55%; improve the research results of the polymerization conversion rate of SBR, can increase the polymerization conversion rate of more than two percentage points, the annual output of rubber can increase more than 8,000 tons, material consumption and energy consumption also decreased significantly.
Careful planning and cost-effective reduction of energy consumption is an important means for the company to increase profits. They have tasted the sweetness of energy saving by implementing small-scale technological reforms with low investment and quick results. The butadiene rubber plant will send the exhaust gas from the tower's original high altitude to the factory boiler for recycling. Through the use of heat energy, it can directly create 500,000 yuan a year, and reduce 160 tons of organic gas emissions, achieving economic and environmental benefits. Win-win.
Through a series of optimization measures, the advanced level of the benchmark, the plant made significant progress in the butadiene rubber plant indicators, from the last ranking of Sinopec rose to second place; SBR benzene plant indicators in the same industry at an advanced level. In 2010, the total processing loss rate of the whole plant decreased by 0.36% year-on-year, the loss of raw materials was reduced by 2,000 tons, and the efficiency was increased by more than 20 million yuan; the annual comparable energy consumption was reduced by 11.5% year-on-year, and the accumulated standard oil was 18,000 tons, saving 70 million yuan.
Keep production, you can't lose quality. In 2010, the plant implemented special research on quality management and improved the product's excellent product rate. The qualified rate of product leaving the factory was 100%. Qilu SBR also won the title of well-known brand products issued by the China Petroleum and Chemical Industry Federation.
The 270,000 tons of production capacity is not the largest in the country, but they must do everything possible to let the equipment complete more tasks. Especially in December of last year, the company's production load reached 130% of the design value.
To make the device as high as possible to increase the load, it is necessary to maintain continuous, efficient, safe and stable operation. Qilu Petrochemical Rubber Factory implements “four-in-one†equipment special protection measures for machinery, electricity, instrumentation and technology, intensive cultivation, 24 hour tracking and inspection of key equipment units, timely understanding of changes in equipment operating parameters, and eradicating equipment failures and accidents. The status avoids unplanned shutdowns and lays a good foundation for large synthetic rubber production.
In order to ensure safe and stable production, they “come out of jealousy and penaltiesâ€. In August 2010, in response to a factory-level production accident, the factory imposed penalties on related personnel, and many were fined tens of thousands of yuan. In September 2010, an employee discovered a major hidden danger in construction and immediately received a reward of 5,000 yuan. They also rewarded each month with good people who discovered potential accidents and avoided accidents. In the whole year, 715 cases of hidden troubles were eliminated, and 837 people were rewarded. The amount of reward was 69,950 yuan.
Because rubber production materials are highly viscous and easy to plug, the seven synthetic rubber post-processing production lines have become the bottleneck restricting the high-load production of the whole plant. The electromechanical integration class responsible for maintaining the operation of the production line put forward the concept of “predictive maintenanceâ€, carefully inspected the production line, discovered problems in advance, and handled the equipment in advance. The failure of the equipment was reduced by 50%, and more effective production time was obtained for the device. The degassing tower of the core equipment of the 100,000-ton/year styrene-butadiene rubber plant put into operation in June 2009 has been extended from less than one week in the initial driving period to more than 150 days, and the daily output of the plant has been increased from 240 tons to 380 tons.
In the fourth quarter of 2010, the factory carried out a special labor competition for increasing production of rubber according to the situation of high market prices for rubber. The rubber production hit a new high every month, especially in November and December of last year, creating a new record of 1000 tons of Nissan rubber. Record.
In respect of raw material supply, the plant optimized the storage of the tank farm and reconstructed the process of receiving the carbine butadiene, which increased the butadiene storage capacity from 3,000 tons to 5,500 tons, and reserved sufficient raw materials for high-load production. At the same time, we strengthened the management of product out-putting and value transfer, actively coordinated external units such as sales and transportation, and ensured that products were delivered in a timely manner.
In order to achieve efficient operation of the plant, the plant completed 14 scientific research and development projects throughout the year. After the development of the APC advanced control system for the secondary extraction plant, the fluctuation of key process parameters was significantly reduced. Through optimized operations, the butadiene yield was improved. Increase 0.54%, energy consumption decreased by 1.55%; improve the research results of the polymerization conversion rate of SBR, can increase the polymerization conversion rate of more than two percentage points, the annual output of rubber can increase more than 8,000 tons, material consumption and energy consumption also decreased significantly.
Careful planning and cost-effective reduction of energy consumption is an important means for the company to increase profits. They have tasted the sweetness of energy saving by implementing small-scale technological reforms with low investment and quick results. The butadiene rubber plant will send the exhaust gas from the tower's original high altitude to the factory boiler for recycling. Through the use of heat energy, it can directly create 500,000 yuan a year, and reduce 160 tons of organic gas emissions, achieving economic and environmental benefits. Win-win.
Through a series of optimization measures, the advanced level of the benchmark, the plant made significant progress in the butadiene rubber plant indicators, from the last ranking of Sinopec rose to second place; SBR benzene plant indicators in the same industry at an advanced level. In 2010, the total processing loss rate of the whole plant decreased by 0.36% year-on-year, the loss of raw materials was reduced by 2,000 tons, and the efficiency was increased by more than 20 million yuan; the annual comparable energy consumption was reduced by 11.5% year-on-year, and the accumulated standard oil was 18,000 tons, saving 70 million yuan.
Keep production, you can't lose quality. In 2010, the plant implemented special research on quality management and improved the product's excellent product rate. The qualified rate of product leaving the factory was 100%. Qilu SBR also won the title of well-known brand products issued by the China Petroleum and Chemical Industry Federation.
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