By the end of March this year, the first domestic synthesis gas production unit that switched from heavy oil to coal water slurry passed a one-year operational test at Zhejiang Juhua Synthetic Ammonia Plant. According to recent data, the cost of gasification has dropped by 50%, while synthetic ammonia output has increased by 24%. The plant also manages nearly 30,000 tons of industrial wastewater annually. This breakthrough in coal-based multi-component slurry technology not only transformed the raw material supply chain but also enabled full recycling of gasification wastewater, delivering significant energy savings and emission reductions. It serves as a valuable reference for similar enterprises.
Under China's current "coal-to-oil" energy strategy, chemical companies are accelerating the adoption of advanced, eco-friendly technologies to phase out outdated production methods. In recent years, some Chinese firms have imported Texaco technology, which can cost up to 150 million yuan. However, due to high investment costs for coal-water slurry technology and the lack of existing facilities for converting oil-based feedstocks into coal slurry, Juhua Synthetic Ammonia Plant invested over 20 million RMB to retrofit its gasification system. They developed a process using petroleum coke and coal mixtures, gradually shifting to a fully coal-based raw material route, and successfully established an industrialized technology for replacing heavy oil with coal-based multi-component slurry.
This is the first such technology in China. During its development, the plant overcame eight technical challenges related to coal water slurry transportation and nozzles, implemented 14 technological upgrades, and carried out eight innovations on the gasifier. To address issues like the uneven quality of bituminous coal and limited coal types suitable for gasifiers, they blended burned coal in certain proportions. By optimizing slurry moisture stability, oxygen ratio selection, and control mechanisms, they improved the reliability of the process. This allowed them to keep coal consumption within a reasonable range, ultimately achieving successful implementation of the coal-water slurry gasification technology.
The industrialized technology has introduced several new innovations, including a solidification and slagging process for coal-water slurry gasification and a heat preservation system for gasifiers, such as a detachable quench chamber. These improvements not only make maintenance easier and help monitor production conditions, but also reduce equipment manufacturing costs by 30%. Additionally, the plant’s closed-loop sewage recycling system enables full reuse of gasification wastewater and treats 70 tons of imported organic wastewater daily. Its environmental protection technology has reached an advanced level domestically.
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