Tianjin Petrochemical's No. 2 polypropylene plant has worked hard to reduce costs and increase efficiency

Since the beginning of this year, Tianjin Petrochemical's No.
2 polypropylene plant has been market-oriented, advanced benchmarking, tapped into its potential, and integrated crew cost accounting into production and operation to effectively improve cost management and achieve cost reduction and efficiency enhancement
.

On the basis of stable operation, internal training to reduce costs

On July 3, in the control room of the polypropylene plant, Dou Yinjie, an internal operator, was focusing on adjusting the DCS
.

Starting from the stable operation of the device, the polypropylene workshop comprehensively sorts out the problems that occur after the start-up, formulates improvement measures, assigns the responsible person, and goes all out to improve the production stability of the device
.
Strictly control product quality and expand market share with high-quality products
.

On the premise of ensuring quality, strictly monitor the amount of additives added to avoid excess cost of additives; by regularly switching the method of regenerating the propylene drying bed, the water content in propylene is reduced, the catalyst activity is improved, and the amount of catalyst is reduced, so as to reduce the three cost of agent; optimize process parameters, reduce the amount of circulating water as much as possible on the premise of ensuring heat exchange requirements, and plan to transform the condensate line of the flash line, increase the pipeline pump, increase the recovery of condensate, and reduce the amount of steam; optimize propylene Refining system operating parameters and regeneration plan to reduce the loss of propylene regeneration
.

The workshop also compared the financial statements such as the "Plant Cost Table" and "Polypropylene Price List", focusing on the item-by-item decomposition of the direct material cost, direct auxiliary material cost, direct power cost and by-product deduction cost of No.
2 polypropylene plant
.
Through benchmarking, 9 influencing factors including return gas, depreciation, and circulating water were summed up.
The workshop found the reasons for 6 controllable indicators and formulated rectification measures
.

Taking the optimization of product structure as the driving force to see the market and tap the potential

"We need to calculate the production cost and marginal benefit of each brand one by one, rank them according to the contribution value of profit or loss reduction, optimize the monthly production scheduling plan, and expand the output of new products
.
" Wang Linlin, director of the polypropylene workshop, arranged optimization measures at the weekly work meeting
.

The workshop keeps a close eye on the market vane and makes dynamic adjustments based on the optimization of product structure
.
They optimize product scheduling and reduce transition material yields
.
Through optimized production scheduling, each brand adopts the method of continuous production across months and increasing monthly output, so that the monthly output of small brands can meet the multi-month sales output, and the new products in mass production can achieve continuous production for at least two months, thereby reducing the cost of production.
The goal of brand switching frequency and reduction of transition material production
.

At the same time, it is in close contact with new product developers and downstream customers to grasp the changes in downstream market demand as soon as possible
.
They strengthened the calculation and increased the output of high-efficiency products such as thin-wall injection molding series PPH-M70, PPH-MP70 and fiber material PPH-Y26
.

In May, the proportion of special materials for new products scheduled for No.
2 plant reached 100%
.
In June, the workshop continuously produced 6 new products, among which the new PPR-M80 of random injection plastics achieved the first trial production
.
In the first half of the year, the No.
2 polypropylene plant completed a production of 86,700 tons, of which 72,500 tons of special materials for new products, the proportion of new products was 83.
6%, and 10 grades were produced, including 9 new special grades
.

Take fine management as the starting point to enhance the cohesion of consciousness

Focusing on small things, detailed management is an important starting point for polypropylene workshops in terms of energy saving and cost reduction
.
They formulated the "Department of Responsibilities for the Implementation of Energy Saving in Installations", which included all energy consumption in production and life into the assessment, assigned various regional responsibilities for active consumption to people, and made up their minds to cut down the "hard bones" of energy conservation and cost reduction
.

The workshop organizes management personnel and backbones to hold a special meeting on energy conservation, finds the crux, prescribes the remedy, formulates energy conservation goals, divides the consumption of public works into 4 categories and 6 sub-items, and formulates 17 energy-saving measures
.
Take the office building, No.
1 device, and No.
2 device as units to divide the area, set up an energy-saving tackling team with the participation of professional groups, teams, and maintenance units, clarify the lead responsible person, hold regular meetings to improve optimization measures, and organize management personnel to check energy conservation on site The implementation of the measures, through the implementation of supervision and assessment, stimulated the enthusiasm of all employees to save energy
.
In terms of electricity consumption, they stipulated the time for lighting on and off in the installation area, and the non-essential lighting in the office building and control room should be turned off in time
.

In the process of saving steam and nitrogen, the leakage points are eliminated by checking the valve packing, flange, guide shower and other parts on site.
At the same time, the user's consumption and consumption are reduced in time according to the change of external temperature
.
In addition, the workshop formulates detailed water-saving measures, and requires operators to check the on-site domestic water and production water pipelines during the daily inspection process, and eliminate leaks in time
.
They also focused on the implementation of water-saving measures at key points, especially the granulation and pelletizing water tank D806 to be cleaned at least once every 4 hours to reduce overflow and water replenishment
.