By the end of March this year, the first domestic synthesis gas production unit that transitioned from heavy oil to coal water slurry successfully completed a one-year operational test at Zhejiang Juhua Synthetic Ammonia Plant. According to recent data, the cost of gasification has been cut by 50%, while synthetic ammonia production has increased by 24%. The plant also manages nearly 30,000 tons of industrial wastewater annually. This breakthrough in coal-based multicomponent slurry technology not only transformed the raw material source but also enabled full recycling of gasification wastewater, delivering significant energy savings and emission reductions. It serves as a valuable reference for similar enterprises looking to modernize their processes.
In line with China's national "coal-to-oil" energy strategy, chemical companies are accelerating the adoption of advanced and environmentally friendly technologies to phase out outdated production methods. In recent years, some Chinese companies have imported Texaco technology, which can cost up to 150 million yuan. Given the high investment required for current coal-water slurry technology and the lack of existing facilities converting oil-based feedstocks to coal-water slurry, Juhua invested over 20 million RMB to retrofit its oil and gasification facilities. They developed a process using petroleum coke and coal mixtures, gradually shifting to a fully coal-based raw material route, and ultimately established a proprietary coal-based multi-component slurry technology for syngas production.
This is the first such technology in China. During the innovation process, Juhua tackled eight technical challenges related to coal water slurry transportation and nozzles, implemented 14 technological upgrades and eight innovations on the gasifier, achieving several breakthroughs. Due to the uneven quality of bituminous coal, which poses challenges for gasifier compatibility, the plant blended it with a certain proportion of burned coal. By optimizing slurry moisture stability, selecting the right oxygen ratio, and enhancing control systems, they improved the reliability of the process, keeping coal consumption within an acceptable range and ensuring the success of the coal-water slurry gasification project.
The industrialized technology has introduced new processes, such as solidification and slagging of coal-water slurry gasification, and a heat preservation system for gasifiers, including a detachable quench chamber. These improvements not only simplify maintenance and monitoring but also reduce equipment manufacturing costs by 30%. Additionally, the plant’s closed-loop sewage recycling system enables full reuse of gasified wastewater and processes 70 tons of imported organic wastewater daily. Its environmental protection technology now ranks among the most advanced in the country.
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