智能工厂实践白皮书

序 言 当前，推动数字经济和实体经济融合发展已成为助推我国经济高质量发展的重要途径。无论是对于一个行业，还是就企业自身而言，数字化转型永远都是一项需要远瞻视角、稳步推动的事业，无法一蹴而就。 作为一家世界级的新能源、新材料高新技术产业集团，多年来，盛虹坚定做绿色高质量发展的引领者和产业转型升级的探路者，不断探索如何充分利用数字化、智能化技术，提高生产过程和运营的安全、可靠、高效和可持续，以提高企业的核心竞争力。 开启斯尔邦石化PDH的智能工厂试点项目是一个非常好的契机。我们期望通过数字化转变项目运营理念，优化组织结构和岗位职责，以实现高效运行和管理，并借由工艺技术和智能化技术的深度结合，以PDH装置为原点，在石化行业内探索以装置为核心基础的绿色化、数字化、智能化最佳实践。 霍尼韦尔在流程工业深耕数十载，在自动化、数字化创新解决方案，以及石化炼化工艺技术等领域都有着深厚积淀和独到优势，是盛虹多年来理念同频、志同道合的合作伙伴。2021年初，我们的PDH丙烷脱氢装置决定采用霍尼韦尔工艺技术，双方深入探讨了在装置实施数字化、智能化的业务目标和实施路径。 经过近两年的持续建设和运营完善，如今，我们很欣慰地看到，当时的许多设想都已经走进现实，成为了我们项目实际生产运营的一部分。同时，我们也欣喜于将这次数字化转型的探索历程与实践硕果毫无保留地同广大的行业伙伴分享。 我们希望这本白皮书能够成为国内外的石化和流程工业同行可以借鉴的、务实的数字化转型实践参考，用前沿的数字化技术塑强企业的盈利性和生存能力，在激烈的市场竞争中脱颖而出。希望我们的成果能够助推整个石化产业引领高质量发展的新时代。 目 录 序言···························································································································································································· 2 第二章 破局：双“技”融合助力卓越运营························································································ 7 第三章 实践：斯尔邦丙烷脱氢（PDH）标杆工厂····································································· 9 项目建设目标········································································································································································· 10实施路径与建设成果·························································································································································· 11a.控制系统性能监视与运维CPM ······································································································································ 12b.先进控制系统APC ····························································································································································· 12c.丙烷脱氢工艺霍尼韦尔UOP生命周期服务················································································································ 12d.现代化中控室······································································································································································· 13e.智能报警管理系统······························································································································································ 13f. PDH装置碳排放监控························································································································································ 14g.智能生产管理执行系统（Honeywell MES）··········································································································· 14项目效益·················································································································································································· 15 第四章 展望：流程工业 “质”胜未来································································································ 16 关于盛虹石化································································································································································· 18 关于霍尼韦尔································································································································································ 19 当前石化行业的机遇与挑战第一章洞察 石化行业要想实现高质量、可持续发展之路，就需要采用更为“与时俱进”的手段和方法，利用全球领先的数字化技术持续提升装置和工厂的自动化水平，加速企业数字化进程，以全面提高产能效益、生产精益管理、精准碳排监控和企业管理的水平。 随着社会经济的高速发展，在过去几十年里，我国石化产品的市场需求和产能一直保持快速的增长势头。从整个工业体系看，石化产业作为支柱产业的重要性日益凸显，《2022年中国石油和化学工业经济运行报告》显示，石化产业规模以上企业营收占全国规模以上工业总收入的12%。从全球市场来看，2022年，我国炼油总产能达9.2亿吨/年，已成为世界第一炼油大国；乙烯产能在全球乙烯产能占比增至21.3%，继续保持世界最大乙烯生产国地位；合成树脂、合成橡胶、合成纤维产量均连续多年稳居世界第一1。 动石化化工行业高质量发展的指导意见》，意见指出，到2025年，石化化工行业要基本形成自主创新能力强、结构布局合理、绿色安全低碳的高质量发展格局2。 然而，石化行业作为一个传统行业，具有周期性特点，每隔一段时间便会出现产能过剩的矛盾。加上最近十年来，整个人类社会数字化及可持续发展进程的加快，这个周期的出现越来越短。据石化联合会发布的《2023年度重点石化产品产能预警报告》，包括乙烯、丙烯、乙二醇、对二甲苯等在内的众多化学品正处于产能投放高峰期，多数产品产能将出现相对过剩。 随着产品供给日益丰富，行业结构调整进一步加快，我国石化化工行业已站在新起点，开启由石化化工大国向石化化工强国迈进的新阶段。在2022年3月，工业和信息化部等六部门发布了《关于“十四五”推 除此之外，石化企业还面临着更为严峻的市场不确定性、运营安全性、绿色双碳以及人力资源等多重挑战： 置身于不确定性陡增的乌卡时代（VUCA――易变性、不确定性、复杂性、模糊性），重资源投入、连续型操作的石化企业不得不面对更为棘手的地缘政治风险、全球通胀压力等带来的市场波动和不确定性，这对于企业自身的韧性与适应力都提出了更高的要求。 市场不确定性增加 随着石化产业价值链的不断延伸，工厂的运营复杂程度持续攀升，决策愈发困难；此外，作为高危、高风险行业，石化生产流程的变量繁杂，受原料、运行工况、设备状态等不确定因素干扰大，许多企业依托现有的工厂装置基础，已经越来越难以满足高安全性的需求。 运营决策与安全性 在“双碳”政策持续推进下，《关于“十四五”推动石化化工行业高质量发展的指导意见》中提出，到2025年，大宗产品单位产品能耗和碳排放明显下降，挥发性有机物排放总量比“十三五”降低10%以上。同时2022年8月，工业和信息化部等三部门印发了《工业领域碳达峰实施方案》，提出要加快推进工业绿色低碳转型，切实做好工业领域碳达峰工作。 低碳可持续 截 至2022年 末， 我 国60岁 及 以 上 人 口 达2.8亿 人， 占 全 国 人 口 的19.8%³，已然进入人口老龄化社会。然而石化企业对于管理、工艺、控制、IT等各领域的人才需求巨大，人员老龄化、专业人才缺失，以及新员工培养难等问题日益凸显，都会给行业向阳发展带来压力。 除了大量聚焦过程控制、生产管控、企业管理的成熟的数字化解决方案外，AIGC、机器学习、XR技术，以及5G/6G、物联网等数字化技术均已经开始在工业生产领域得到不同程度的应用。同时，ESG（环境、社会和公司治理）理念这两年在全球领域的迅速崛起也给石化企业的数字化转型提供了新的维度――数字化是践行这一长期主义的重要手段，能够有效帮助炼油、石化化工行业节约能源和减少碳排放5。企业还能通过建立碳资产的数字化管理体系，不断探索低碳资产与创新发展的结合路径，驱动绿色转型的业务增量，提高资源与资产利用与价值创造效率，并实现运营和生产的端到端优化。 面对这些挑战，石化行业要想实现高质量、可持续发展之路，就需要采用更为“与时俱进”的手段和方法，利用全球领先的数字化技术持续提升装置和工厂的自动化水平，加速企业数字化进程，以全面提高产能效益、生产精益管理、精准碳排监控和企业管理的水平。 时至今日，“数字化转型”已经行至深水区，迈向了新的发展阶段，全球企业对于数字化转型的重视和资金投入也达到了前所未有的高度。202