Smart Upgrade of the 66,000 Nm³/h Air Separation Unit at Southwest Copper: Pioneering a New Era of Autonomous Operation for Large-Scale Air Separation Plants
Release time:
2024-12-27
Recently, the smart factory construction project—implemented by China Air Separation Engineering Co., Ltd. (hereinafter referred to as “China Air Separation”)—has achieved breakthrough progress in the Southwest Copper Industry’s 66,000 Nm³/h air separation unit EPC project, which has now been officially put into operation. This milestone sets a new industry standard, propelling large-scale air separation units into a new era of autonomous operation and ushering in a fresh chapter of intelligent transformation.
Industrial Intelligence Core: Innovative Integration Upgrades the Air Separation “Brain”
This air separation unit deeply integrates a number of cutting-edge technologies from the air separation industry, achieving significant breakthroughs in intelligence. At the control level, by breaking away from the traditional reliance on single systems—DCS (Distributed Control System) and SIS (Safety Instrumented System)—the unit introduces an APC (Advanced Process Control) operation navigation system. This innovative combination endows the air separation unit with a sophisticated and intelligent “central brain” that seamlessly integrates process expertise, control intelligence, and operational experience. The operation navigation system, equipped with a “one-click start” function, autonomously and systematically guides the startup process, ensuring that every step is executed precisely and flawlessly, thereby greatly enhancing both startup efficiency and safety.
Once the oxygen product reaches the preset target, the APC advanced control system takes over the control baton. Leveraging its outstanding real-time analytical capabilities and intelligent adjustment strategies, it flexibly adjusts the load according to varying production conditions, precisely matching demand and enabling the unit to operate autonomously and efficiently, thereby delivering customers an enhanced experience in terms of both production efficiency and cost optimization.
Smart-Driven Breakthrough: Rapid Response, Building an Efficient Control Model
Faced with challenges such as the large scale of the project, lengthy process flows, numerous equipment units, and higher requirements for operators, the client set forth the goal of achieving “autonomous” operation of the oxygen-generation unit through intelligent upgrades. The Intelligent Upgrade Task Force of the Party Branch for Air Separation Gases in China swiftly responded, issued a solemn commitment, meticulously developed an implementation plan, and organized multiple rounds of in-depth exchanges among experts from the process and control fields. Together, they selected the most suitable control platform and designed highly efficient operational procedures and control models.
After numerous rounds of rigorous testing and optimization, we have successfully developed a mature and highly efficient control model. Before the commissioning trial, the smart technology task force once again worked closely with the client to integrate the client’s operational experience into the control model, thereby further refining and optimizing even the most complex operational procedures. During the first full-scale commissioning trial, the operation navigation system was put into use. As soon as the operators pressed the start confirmation button, the air separation unit automatically and systematically carried out all its pre-set operations and confirmations, following the predetermined control model.
In addition, the project is equipped with an advanced intelligent cryogenic liquid filling system that integrates AI-powered image recognition, smart weighing, and intelligent filling equipment, enabling “one-card” management throughout the entire process—from inbound to outbound logistics. This system not only significantly boosts filling efficiency but also minimizes safety risks, providing robust assurance for the rapid circulation and safe transportation of products.
In recent years, China Air Separation has achieved remarkable results in the field of smart chemical plants, having undertaken and successfully implemented several smart plant projects, including the Hebei Natural Gas LNG Storage and Peak-Shaving Station Smart Plant, Sinopec’s high-nitrogen unmanned operation system, and the intelligent centralized control systems for oxygen production at Nangang and Tiangang. Since these projects were successfully put into operation, they have not only strongly promoted the “digital and intelligent” development of the cryogenic industry but have also set a brand-new benchmark for the entire air separation industry, guiding the sector toward a smarter and more efficient future.
Contributed by: Gas Engineering Company, Zhou Fenghua
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