Hubei Xingfa Wins Profit in Pollutants Reduction     

China's leading phosphorus chemical company Hubei Xingfa Chemicals Group Co., Ltd. (Hubei Xingfa, SH: 600141) emerges as a winner among domestic phosphorus chemicals competitors that are worrying about difficulties in treating pollutants and possible cost increase.
   Hubei Xingfa is the largest fine phosphorus chemicals enterprise in China and the largest sodium hexametaphosphate producer worldwide according to the company. It annually produces 1 million tons of fine phosphorus products, 500 000 tons of feed grade calcium phosphate and 2 million tons of phosphorus compound fertilizers. Phosphorus related production is well known as a sector that can bring about serious pollution. China's environmental protection administrations have also paid high attention to the sector. Control policies came one by one (Initial Achievements in Readjustment to Yellow Phosphorus Industrial Policy, CCR2008 No.28, Strict Control on Phosphate Rock Export CCR2008 No.31, China Raises Entry Threshold for Yellow Phosphorus Industry CCR2009 No.2). As a leader in the phosphorus chemical industry, Hubei Xingfa has developed a high effect, energy conservation and environmental friendly way through years' effort. Large input and effective technological innovations brought the group with significant profit and sustainability engine.   
   In the past few years Hubei Xingfa has spent over RMB400 million in conducting energy conservation and pollutants reduction, developing cyclic economy business and clean production, which led to the establishment and operation of around 32 projects such as the reuse of flue heat from phosphorus acid and sodium hexametaphosphate production units, the utilization of flue gas from yellow phosphorus production unit, the project of making feed grade calcium hydrogen phosphate from sodium hypophosphite containing residue, the production of phosphates from wastes of dimethyl sulfoxide production, the intelligentization energy conservation for yellow phosphorus power-driven furnace. These projects help the group annually save 40 000 tons of coal, reduce 800 tons of sulfur dioxide emission while gain a profit of RMB40 million per year. Presently, the group dominates its domestic competitors by its technologies and progresses in the comprehensive utilization of wastes. Hubei Xingfa has achieved 100% comprehensive utilization of solid wastes, 90% utilization of flue gas from yellow phosphorus production unit, 90% recycle and utilization of industrial waste water, reached significant effect in the utilization of flue heat and improved greatly the status of environmental protection and work safety.     

A. The recovery and reuse of flue heat from the polymerization of sodium hexametaphosphate production units

Hubei Xingfa succeeded in the research and development of this technology in April 2006, built up the first recovery unit in its Baisha River chemical plant in December 2006 and put it into service. Other nine similar units in turn came on stream in other plants. A heat exchanger is installed to transfer the heat of the high temperature - 350 degree centigrade - flue gas from the polymerization furnace to the  recycling water for generating saturated vapor that can supply heat to other production units.  
   After renovation, the company consumes 177 KWh of power in producing one ton of sodium hexametaphosphate while outlets 2.03 tons of vapor outside the production unit, compared to the consumption of 0.5 tons of vapor and 189 KWh of power before renovation.
   Hubei Xingfa now owns 12 sets of sodium hypometaphosphate production units, with a total capacity of 60 000 t/a. By using this technology, the company reduces consumption of coal by 25 000 tons per year but contributes to 121 700 tons of vapor that translates to a revenue of RMB9.73 million. It can be said the group makes money from reducing pollutants.

B. Production of phosphates from wastes of dimethyl sulfoxide production

A large amount of waste salts containing sodium nitrate and sodium nitrite will be produced in the production of dimethyl sulfoxide, the treatment of which is a hard issue for domestic producers. In the treatment technology developed by Hubei Xingfa, urea and phosphorus acid is added in the waste salts to react with sodium nitrite, then disodium hydrogen phosphate, carbon dioxide and nitrogen are generated. Disodium hydrogen phosphate and sodium nitrate are extracted to produce sodium triphosphate.
   Hubei Xingfa now operates two lines annually producing 10 000 tons of dimethyl sulfoxide and 3 500 tons wastes containing sodium nitrate and sodium nitrite. In 2007 the company treated with 3 510 tons of wastes, helping to reduce production cost of sodium triphosphate by RMB17.3 per ton. The dimethyl sulfoxide workshop realizes zero emission.

C. Making feed grade calcium hydrogen phosphate from sodium hypophosphite containing residue

In this renovation, the flue gas coming from the yellow phosphorus power driven furnace is used to supply with heat, the residue containing sodium hypophosphite and phosphorus apatite is calcined at high temperature to make feed grade calcium phosphate through solid phase oxidation. The pollution caused by residue is well solved. The group has built a 10 000 t/a feed grade calcium phosphate production line consuming 3 500 tons of sodium hypophosphite residue per year, and acquires annually RMB15 million on sale.

    Hubei Xingfa's experiences illustrates that the phosphorus chemical firms will make profit from conducting energy conservation and pollutants reduction. The economic profit gained can offset the increased investment in renovation. More importantly, the company can hence win public identification and enhance its competitive edge.