Benefits from Reconstruction of Ordos Cosource Chemical Calcium Carbide Furnace

After many years of technological innovation and transformation, the technological level and management level of CALCIUM carbideproduction line of Ordos Tongyuan Chemical Co., Ltd. has stepped up to a new level, resulting in three major benefits, one is to reduce labor costs, the other is to reduce energy consumption, the third is to show environmental protection effect and reduce emissions.

The company is a Calcium Carbide production enterprise jointly invested and constructed by Ordos Power Metallurgy Group Co., Ltd., Shenzhen Mengxin Industrial Co., Ltd. and Tianjin Botian Chemical Co., Ltd.

The company had 6 25500 KVA semi-hermetic internal combustion calcium carbide furnaces with an annual capacity of 300,000 tons. Beginning in October 2015, the company has carried out the hermetic transformation of all calcium carbide furnaces. Six sets of purification devices, one gas-fired lime kiln with a daily output of 500 tons, three sets of closed cooling towers, one set of proportioning system and automatic centralized control system have been built, with a total investment of 169 million yuan. Gao Zhixiang, general manager of Tongyuan Chemical Co., Ltd.

introduced that on March 28, 2016, the first retrofitted sealed carbide furnace was ignited and the retrofitting of all equipment and devices was completed by the end of June 2016. Before the transformation, the company's calcium carbide furnace was a semi-closed furnace, which polluted the environment greatly. After the transformation into a closed furnace, the company neutralized the tail gas and regenerated it to produce white ash. The tail gas achieved zero emission, forming a recycling chain, and greatly reduced the production cost.

If white ash is purchased from the market, the price is 310 yuan per ton. Now the cost of producing white ash is 120 yuan to 130 yuan per ton after using tail gas as heat source of producing white ash in gas-fired lime kiln.

Compared with the original budgetary indicators of semi-closed furnaces, the equipment operation rate and process indicators have been well optimized after the transformation. Now all the tasks of technological transformation have been completed. Now the comprehensive benefits of the company's 25500 KVA closed furnaces are basically the same as those of the same industry's 33000 KVA and 40500 KVA furnaces. After technological transformation, under the same market conditions, the company's production cost is reduced and its competitiveness is improved. Gao Zhixiang said that the reformed calcium carbide furnace realized the automation of process, safety interlock, system detection, alarm, machinery and instrument, and realized the automatic monitoring of hydrogen content, oxygen content, Carbon Monoxide and furnace pressure. The company has an independent central control room, and the automation operation level of the closed furnace calcium carbide in the same industry. The furnace is in the leading technological level. On the one hand, the introduction of automation control greatly reduces the workload, from more than 700 people in the past to 575 people at present, which greatly reduces the cost of personnel; on the other hand, the improvement of automation level reduces the labor intensity of employees and effectively evades safety risks.

In addition, after retrofitting the closed furnace of the same source chemical industry, the recovery and utilization of the calcium carbide furnace gas was realized. The purified calcium carbide furnace gas was used as the heat source for the production of lime in the gas-fired lime kiln. The annual energy saving was equivalent to 48,000 tons of standard coal, and the carbon dioxide emission was reduced by 176,000 tons. At the same time, by adopting new technology, improving the automation level of production process, rationalizing power supply system and other measures, the power consumption is 200 degrees/ton lower than before the transformation, the annual energy saving is equivalent to 7500 tons of standard coal, and the carbon dioxide emissions are reduced by 27,000 tons.

In order to do a good job in energy saving and emission reduction, reduce production costs, increase benefits, and meet the new requirements of energy saving, emission reduction and safe production under the new normal conditions, homologous chemical industry relies on automation technology progress to improve resource and energy utilization efficiency, reduce carbon dioxide emissions, and embark on the green sustainable development of "grasping benefits, improving benefits and promoting harmony".