Green & Intelligent Transformation of Traditional Chemicals

As a traditional chemical enterprise, Yunnan Tian’an Chemical once faced common industry problems such as frequent equipment failures, extensive production processes, and high energy consumption. Equipment maintenance relied on “manual inspection + experience judgment”, making it difficult to detect hidden faults, which often led to unplanned shutdowns. To address these pain points, the company promoted the “intelligent transformation & digital upgrade” strategy and built a self-designed online equipment monitoring and diagnosis system, covering 50% of core equipment (such as over 1,000 pieces of equipment and tens of thousands of control points in the synthetic ammonia system). Through 5G and cloud platforms, it realizes automatic collection and remote early warning of abnormal working conditions, and provides scientific diagnosis plans to assist maintenance. As a result, the annual alarm count has decreased by 61%, and the total number of equipment defects and failures has dropped by more than 50%. Meanwhile, advanced process control (APC) technology has been applied to 17 sets of equipment including sulfuric acid, boilers, and coal gasification. Operators have shifted from “frequent adjustments” to “abnormality monitoring”, increasing the comprehensive efficiency of boilers by 1.5% and saving about 2,800 tons of coal annually; the fluctuation deviation of key process parameters in coal gasification and synthetic ammonia equipment has been reduced by 30%, and the standard coal consumption has decreased by more than 1%. In addition, an intelligent operation and maintenance system covering four major specialties (mechanical, static, electrical, and instrumentation) has been constructed, with full coverage of condition monitoring for Class A equipment. The DCS fault handling time has been shortened by 60%, and “unmanned” scenarios such as unmanned weighing in the weighing room and automatic packaging of phosphate fertilizer have been realized, improving weighing efficiency by 50%. It has successfully blazed a new path for high-quality development of traditional chemical industry.

back top
Products
Contacts
WhatsApp
Email