Qilu Petrochemical Acrylic Fiber Plant: Breaking The High Energy Consumption Disadvantage

The benefit of the acrylic fiber industry has not been two days. The market share of acrylic fiber has shrunk again and again under the strong attack of its substitute products. The forced mechanism of the global financial crisis has finally made the long term declining Chinese acrylic fiber industry achieve profit in a severe shuffle. But before the time comes, the post crisis era has arrived.

It is in such a difficult and changeable environment that one of the remaining two dry acrylic fibres factories in China, Sinopec acrylic fiber factory, is still persistently managed through strict, meticulous management and unremitting technical tackling and pformation. It not only makes products irreplaceable, but also breaks the inferiority of the energy consumption of dry polyacrylonitrile widely recognized in the industry, and solves the problem of DMF polluting the environment.

Products can not be replaced

The cross section of dry spinning acrylic fiber (wet acrylic fiber is round) makes it more fluffy, resilient and strong covering ability than wet acrylic fiber.

The same weight of dry spun acrylic fabric is more plentiful and thicker than that of wet acrylic fiber. At the same time, it has smooth surface, natural luster and elegant style.

These unique product advantages make dry acrylic fiber have an obvious irreplaceable nature, especially in the use of plush fur and other advantages, and many varieties are designated as special raw materials.

In a sense, dry spun acrylic fiber itself is a differentiated product in acrylic fiber.

Thanks to the great impact of the global financial crisis, in 2008, Zhejiang Jin Yong and Qinhuangdao two dry acrylic fibres factories were closed down. The domestic dry acrylic fiber production enterprises only have two Qilu Petrochemical acrylic fiber plants and the PetroChina Fushun branch acrylic fiber plant.

At present, the capacity of Qilu Petrochemical polyacrylonitrile plant has been expanded from the original designed annual output of 45 thousand tons to 65 thousand tons, and the product variety is increasingly rich.

Enterprise users are widely distributed in Shandong, Jiangsu, Zhejiang, Hebei, Guangdong and Shanghai.

By vigorously carrying out technical research, the products of the Qilu Petrochemical Acrylic Fiber Plant not only fully played the characteristics of dry acrylic fiber, but also spinnability.

The factory is the only manufacturer capable of producing dry spun acrylic tow, wool and fine denier products in China. In recent years, its tow spinnability has made a qualitative leap, and the sales of tow has increased from less than 1380 tons in 2005 to 20865 tons in 2009.

The factory's existing products include short fiber, tow and wool top three categories, a total of 64 specifications, including 37 short fibers, 10 tow, and 17 top wool.

In order to enhance the ability to resist market risks and realize the sustainable development of enterprises, in recent years, the factory has developed and produced specialized materials for flame retardant yarns, special-shaped cross section fibers, imitation cashmere tops, fine denier products, super high shrinkage wool tops, super high shrinkage wool special tow, super soft super bright acrylic, anti pilling acrylic fiber and other new products, many of which break the long-term dependence on imports in the domestic market.

At present, the plant is developing new products such as colored fibers, color wool tops and flame retardant fibers. The polymerization pilot plant has been built, which will lay a foundation for the enterprises to prepare new products through polymerization and modification, and open up wider space for the development of new products.

Breaking the high energy consumption disadvantage

In 2009, the three consumption of acrylic fiber in the Qilu Petrochemical Acrylic Fiber Plant was 991.95 kg/t, that is, 991.95 kilograms.

It can be seen from the materials of the Qilu Petrochemical acrylic fiber plant that since 2004, the plant has been

From 2006 to 2008, the energy saving of Qilu Petrochemical polyacrylonitrile plant reached 16.7%, 6.46% and 13.85% respectively for the 3 consecutive year, the first place in Leziru branch.

In 2009, in the first 3 years of the situation, the factory saved 5041 yuan of standard oil again and saved 7.26%.

Besides, the acrylonitrile plant of the plant has realized long term optimization operation.

The daily output of fiber has increased from 168.5 tons in 2004 to 185 tons now. The most important index to measure the operation level of the plant is less than more than 40 sets of 100 tons of fiber, which is the best domestic level.

Eradication of DMF pollution

In the industry, the dry acrylic fiber in addition to high energy consumption, the use of solvents DMF pollution problem is also very headache.

In order to solve this problem, the Qilu Petrochemical polyacrylonitrile plant has implemented a large number of DMF recovery and waste gas treatment projects, invested about 6000000 yuan to carry out the DMF recovery leaching tower pformation, and recovered about 300 tons of DMF in the month, resulting in a significant decrease in DMF consumption. More than 800 yuan was invested, and the pformation of the ventilation system of acrylonitrile plant and the treatment of two methylamine odors generated by DMF decomposition and the treatment of exhaust gas in the monomer and tank farm were implemented successively.

An investment of 3 million yuan to complete the ventilation pformation project will be used to recycle the DMF from the emptying gas in order to reduce the air pollution and realize the comprehensive utilization of the "three wastes" resources.

The waste gas treatment works of monomer waste gas and tank area, which are invested at 3 million 500 thousand yuan, are all recovered from the waste gas containing acrylonitrile, methyl acrylate and other materials.

In particular, it is worth mentioning that the two methylamine odor control project, which invested 1 million 500 thousand yuan, adopts the technology of low temperature plasma catalytic oxidation to decompose the two methylamine in waste gas into a simple organic matter with no odor, and then emptying. When eliminating the fishy smell, it can reduce more than 10 tons of organic matter per year.

As a model of new technology for industrial application, the project is the first industrialized application in China. Its effect is obvious. It has been highly appraised by local governments and environmental protection departments for many times, and has begun to be applied in the industry.

Beginning in March 2002, the Qilu Petrochemical Acrylic Fiber Plant realized the pretreatment of sewage and wastewater from the plant, and then sent it to the municipal sewage treatment plant through special pipe network for deep purification.

Through continuous technological progress and meticulous management, DMF consumption of Qilu Petrochemical polyacrylonitrile plant dropped significantly, from 66kg/t in 2004 to about 30 kg/t in 2009, which dropped by 40% over the design value of 50 kg/t, reaching the international advanced level.

In the context of changing the way of development and adjusting the industrial structure, the Qilu Petrochemical Acrylic Fiber Plant is also thinking about the way out in the future and investigating related projects.

At present, the expansion and pformation of acrylonitrile plant in the plant is proceeding smoothly and is expected to be put into operation in June 2011.

At that time, the production capacity of acrylonitrile will increase from 40 thousand tons to 80 thousand tons. It will not only achieve complete self-sufficiency of acrylic materials, but also become a new growth point of the company's efficiency.