Wuxi Petrochemical Resources Reuse
Wuxi Petrochemical once faced a major environmental and energy efficiency issue, as its 300,000-ton oil refining production line released approximately 3.5 million cubic meters of flare gas into the atmosphere annually. This not only led to significant energy waste but also caused severe environmental pollution. To address this problem, the company implemented three key measures aimed at turning waste into value, improving resource utilization, and boosting economic efficiency, while successfully eliminating the use of the tail gas torch.
First, the refinery’s flare gas was repurposed as fuel for the thermal oil furnace in the BPA plant. Through technological upgrades, part of the flare gas was redirected into the furnace, replacing diesel fuel. This change not only prevented the black smoke resulting from incomplete diesel combustion but also saved about 800 tons of diesel per year, generating over 300 million yuan in economic value.
Second, a new 6-ton/hour automatic gas-fired boiler was constructed to replace the old coal-fired boiler. The refinery's tail gas was used as fuel to produce steam for industrial use. This approach reduced air pollution from incomplete combustion of the flare gas and replaced coal consumption, avoiding sulfur dioxide emissions. As a result, more than 10,000 tons of steam were supplied annually with less than 2,000 tons of coal, saving over 1.1 million yuan in costs each year.
Third, the company focused on comprehensive resource utilization by adopting advanced practices from leading oil refineries. After extensive research and testing, they installed a gas separation unit that further refined liquefied gas from the catalytic process to produce high-value propylene. This technical upgrade deepened the processing capacity of the refinery, increased overall resource utilization, and marked a significant step toward transforming the refinery from a fuel-oriented to a value-added operation.
The project required an investment of 28.17 million yuan and was completed successfully in one phase. In its first year of operation, it produced over 8,000 tons of propylene, with a total value exceeding 20 million yuan. More importantly, the technical improvements enhanced the refinery’s tail gas recovery system, ensuring optimal utilization of waste gases and contributing to long-term sustainability.
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