What Factors Should Be Considered In On-Site Gas Production In Chemical Industry Plants
2025-02-12
In the chemical industry, on-site gas production at factories is a complex and challenging process that involves a comprehensive consideration of multiple factors. To ensure safety, efficiency, and compliance, a thorough analysis and design from technical, economic, safety, environmental, and regulatory perspectives are necessary.
Firstly, the selection and supply of raw materials are the foundation of gas production process design. Depending on the specific process requirements, commonly used raw materials include coal, natural gas, biomass, and petroleum coke. The cost, availability, suitability, and stability of the supply of each raw material need to be thoroughly evaluated to avoid production disruptions due to raw material shortages or quality fluctuations. In addition, the pre-treatment requirements of raw materials, such as crushing, drying, or desulfurization, may increase the complexity and cost of the process, so proper planning of the pre-treatment steps is necessary. When selecting the process route, different processes must be weighed against each other based on actual needs. Common gas production processes include coal gasification, steam reforming, partial oxidation, and water electrolysis for hydrogen production. The choice of these processes must not only consider conversion efficiency but also assess energy consumption, product purity, by-product handling, and other factors. Additionally, optimizing the process design is critical. Adjusting reaction conditions (e.g., temperature, pressure, catalysts) and utilizing waste heat recovery technologies (e.g., waste heat boilers) can effectively improve gas production efficiency and reduce energy consumption. The flexibility of the process route is also an important factor to consider. The ability to adapt to different raw materials or produce various gases (e.g., syngas, hydrogen, CO₂) can enhance the adaptability and cost-effectiveness of production. The selection of equipment and its reliability are also key factors influencing the stability and economy of on-site gas production . Core equipment such as reactors, compressors, separation towers, and purification devices (e.g., PSA, membrane separation) must be made of materials resistant to high temperatures and corrosion to ensure long-term stable operation under harsh conditions. Moreover, redundant equipment design is an important measure to ensure the continuous operation of the factory. For critical equipment like compressors, backup systems should be in place to avoid production stoppages due to single-point failures. Additionally, selecting suppliers with mature technologies and good after-sales service can ensure smooth maintenance and upgrades of the equipment. In terms of safety risk control, gas production processes often involve high temperatures, high pressures, and flammable or explosive gases, so strict explosion-proof designs are necessary. Gas leakage detection devices (e.g., infrared sensors) and emergency shutdown systems (ESD) should be installed. Operators must strictly follow operating procedures and regularly conduct safety drills to ensure that they are equipped with the necessary protective equipment. Emergency plans should be developed to address potential accidents, such as fires, gas leaks, poisoning, etc., and appropriate firefighting equipment and neutralizing agents should be provided. Environmental protection and emissions management are also crucial. On-site gas production processes in chemical factories generate waste gases, wastewater, and solid waste, so effective waste gas treatment measures, such as wet desulfurization, denitrification (SCR/SNCR), and dust removal technologies, must be implemented. Wastewater treatment should not be neglected, with acidic wastewater requiring neutralization and heavy metals being recovered for reuse. Biochemical treatment systems should meet discharge standards. Solid waste, such as ash and spent catalysts, should be disposed of in accordance with resource utilization or compliant landfill principles. Additionally, given the global strict regulation of carbon emissions, the application of carbon capture technology (CCUS) and green hydrogen technologies can help achieve carbon neutrality goals and reduce carbon footprints. Energy efficiency and cost control are at the core of the economic viability of gas production processes. Technologies like heat integration, efficient catalysts, and variable frequency drives can significantly reduce energy consumption and optimize electricity and steam usage efficiency. In cost accounting, it is essential to cover various expenses, including raw materials, energy, equipment depreciation, labor, and environmental treatment, and to assess the total lifecycle costs to ensure reasonable investment returns. At the same time, evaluating the factory’s capacity in relation to market demand is necessary to avoid overinvestment or capacity shortages. Regulatory and standard compliance is a strict requirement for every chemical factory. The factory must comply with local and international regulations, such as the “Regulations on the Safe Management of Hazardous Chemicals” and the “Comprehensive Emission Standards for Air Pollutants,” and obtain necessary safety production permits and environmental impact assessments (EIA) approvals. Additionally, international standards such as ISO 14001 (Environmental Management) and ISO 45001 (Occupational Health and Safety) should also be taken into account. As technology continues to develop, automation and digitalization have become significant trends in modern chemical factories. By adopting advanced control systems (e.g., DCS/SCADA), real-time monitoring and optimization of on-site production can be achieved. Integrated AI algorithms can adjust process parameters based on real-time data to improve production efficiency and stability. Additionally, predictive maintenance technology, through monitoring indicators such as equipment vibration and temperature, can provide early warnings for potential failures and reduce downtime. Data security is also a key aspect of digital factories, and effective measures must be taken to prevent industrial control systems (ICS) from cyberattacks. The selection of the factory site and the construction of infrastructure are equally important. The factory should be located in an area with convenient transportation and close to raw material suppliers or major users to reduce logistics costs. Additionally, stable power supply, adequate water sources, and steam/cooling systems must be available. Logistics planning should include the rational design of raw material and product transportation routes and consider the capacity of storage facilities. Regarding human resources, chemical enterprises need to equip themselves with professionally skilled engineers, technicians, and safety management teams. Regular training on operations, emergency responses, and safety protection is essential to ensure employees can handle various production and safety challenges. Corporate culture development is also very important, with a focus on reinforcing the “safety first” concept and establishing a safety management system involving all employees. Market demand and product adaptability are also key factors in the gas production process. Based on market demand, gas purity, pressure, and supply methods should be adjusted flexibly. Especially with the rapid growth of hydrogen energy demand, modular production line designs enable enterprises to quickly respond to market changes. In terms of lifecycle management, the factory should reserve space or interfaces for future capacity expansion or technological upgrades. Furthermore, the environmental management of equipment retirement should be planned in advance to avoid residual pollution. Deeper considerations also include geopolitical risks, particularly in the case of high dependence on raw material imports, where international political changes may lead to supply risks. Moreover, technological innovation should not be overlooked, and attention should be given to new gasification technologies and electrochemical hydrogen production to maintain the enterprise’s competitiveness. In the context of the circular economy, the resource utilization of by-products, such as CO₂ for urea synthesis, is also an important path for sustainable development. In the on-site gas production process , chemical industry factories must comprehensively consider raw material selection, process design, equipment selection, safety management, environmental compliance, and other factors to achieve safe, efficient, and sustainable production goals. Huazhong Gas is a professional on-site gas production company in China . We conduct on-site assessments based on the factory location and customize solutions according to the required products. By adopting advanced products and construction technologies, we help factories quickly meet their needs. We welcome discussions with you.HEADLINES
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