As of May 10th, the polypropylene unit at PetroChina's Daqing Petrochemical has achieved a continuous, safe, and stable operation of 1,008 days, setting a new record for long-term operation of similar domestic facilities. This milestone marks a significant breakthrough in the operation and management of polyolefin units for Daqing Petrochemical, accumulating valuable experience and providing practical reference for the industry.
PetroChina's Daqing Petrochemical focused on addressing the bottleneck issues restricting the polypropylene unit's operation. Through a dual approach of systematic technical research and refined management, the company resolved operational challenges one by one, achieving a leap from the unit's historical best performance to a new industry benchmark. During this operating cycle, the unit has cumulatively produced over 300,000 tons of polypropylene products.
It is understood that this polypropylene unit at Daqing Petrochemical operates on a single line, with tightly connected sections for polymerization, flash evaporation, and granulation. Any fluctuation in a single link could lead to a full shutdown, making long-term continuous operation extremely challenging. The company overcame technical hurdles and achieved stable operation through three key measures:
1. **Precise Problem-Solving and Technological Innovation to Overcome Operational Bottlenecks:** Inaccurate pressure indication in the loop tubular reactor and declining heat exchange capacity in the reboiler were two major chronic issues hindering long-term operation. The Chemical Department No. 1 at Daqing Petrochemical established a dedicated task force. They innovatively adopted a "dual-pressure comprehensive judgment method" and optimized interlock strategies, achieving precise control over core process parameters and significantly enhancing operational stability.
2. **Refined Control and Scientific Maintenance to Fortify Stability:** Daqing Petrochemical implemented millidegree-level control over polymerization reaction temperature, stabilizing it within an extremely narrow range of 0.3 degrees Celsius. Concurrently, the company vigorously promoted a predictive maintenance model. For key equipment such as the extruder granulator and recycle gas compressor, online monitoring systems were used to accurately assess operating status, allowing for the early detection and elimination of potential issues. These measures effectively improved unit operation quality, reducing material consumption to a record low of 1,006 kilograms per ton.
3. **Meticulous Cultivation and Talent Development to Forge a Competent Team:** Daqing Petrochemical comprehensively enhanced the skill levels and emergency response capabilities of its operators through methods including mentorship, practical drills, differentiated training, and incentive-based assessments. Chemical Department No. 1 also established a clear emergency authorization mechanism with defined responsibilities. This mechanism authorizes shift leaders to make scientifically informed decisions immediately in critical situations, effectively improving "one-minute" response capabilities and building a solid defense line for the unit's safe and stable operation.
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