The first set of Shell oil-to-coal plant will save millions of investment monthly Hubei Hubei Shuanghuan
Since May 17th, the first coal gasification ammonia production plant at Hubei Shuanghuan Science and Technology Co., Ltd. successfully started operations, marking a major milestone for the company. This new facility has helped the company save approximately RMB 1.09 million per day. Following a loss of RMB 10 million in April, the company managed to break even in May, and by June, it turned profitable. This turnaround completely reversed the operational challenges caused by rising oil prices and significantly enhanced the company’s core competitiveness and its ability to withstand market fluctuations.
The coal gasification ammonia plant introduced by Shuanghuan is based on Shell’s advanced pulverized coal gasification technology. Designed by China Wuhuan Chemical Engineering Company, it was the world's first of its kind. According to the head of the Technical Department, the total investment in the project reached 700 million yuan. The core equipment includes the Shell pulverized coal gasifier, ammonia synthesis tower, steam boiler, filter, and scrubber tower. The gasifier itself was manufactured by Dalian Jinzhou Heavy Machinery Factory. The system processes 1,000 tons of coal daily, producing an average of 1,800 tons of soda ash and ammonium chloride products.
This advanced facility boasts high technological content and automation, allowing it to adapt to various types of coal. Compared to other similar technologies, it offers significant advantages in raw material consumption, carbon conversion rate, and thermal efficiency. Additionally, the by-products such as fly ash and residue are of high quality and can be used as raw materials for cement production. The system also features a highly efficient desulfurization unit that meets European environmental standards, effectively solving long-standing issues with carbon black emissions. The successful commissioning of this plant is expected to serve as a model for the industry and provide valuable guidance for raw material selection in China's synthetic ammonia production.
Due to the sharp rise in international oil prices in recent years, many domestic synthetic ammonia plants relying on oil as a feedstock have been forced to shut down due to heavy losses. In 1997, Shuanghuan decided to transition from oil to coal and collaborated with Shell and Wuhuan Technology for nearly a decade to build the world's first coal gasification ammonia plant. This marked the first installation of Shell's coal gasification technology in China. The economic benefits of the project are mainly attributed to a significant reduction in both raw material and pollution control costs. While oil-based ammonia production requires 0.84 tons of oil per ton of ammonia, the coal-based process only needs 1.45 tons of coal. This results in a cost saving of about 2,000 yuan per ton of synthetic ammonia. Moreover, the plant was designed to meet European environmental standards, achieving zero wastewater discharge and eliminating the need for additional pollution control measures.
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