Under the background of increasingly fierce market competition and continuous fluctuation of energy cost, how to reduce production cost, stabilize key indicators and improve resource utilization efficiency has become a key issue to promote high-quality development of enterprises. Since this year, Donghua Science and Technology has been closely following the requirements of Shandong Energy Group and New Material Company for reducing costs and increasing efficiency, insisting on the substitution and utilization of raw materials as an important breakthrough to reduce production costs and improve environmental protection indicators, taking system optimization as an important grasp of stable operation, and promoting technological transformation, process optimization and coordinated disposal as a whole. Promote the continuous optimization of coal consumption indicators in clinker production and the steady improvement of resource utilization efficiency, so as to inject strong momentum into enterprises to reduce costs and increase efficiency.
In addition to traditional coal combustion, a number of "unconventional resources" are gradually becoming an important alternative fuel source for clinker production. Substitution of
raw materials and fuels is an important way to reduce coal consumption and promote the recycling of resources. "The cost of coal accounts for about 45% of the total cost of clinker, so coal is an important breakthrough in our fuel substitution work." Zhang Yong, vice minister of the company's clinker division, said. Focusing on the goal of reducing coal consumption per unit clinker, Donghua Science and Technology continued to expand the application scope of alternative fuels, effectively reducing the consumption level of traditional coal through stable operation of wet fly ash, high calorific value fly ash and other calorific value materials, and the standard coal consumption from January to March this year was 7.5% lower than that of last year.
While promoting the application of alternative fuels, the company actively promotes the stable operation of co-disposal of solid and hazardous wastes, incorporates calorific industrial waste liquid into the system operation system, realizes the co-promotion of resource reuse and energy substitution, and continuously broadens the space for cost reduction and efficiency enhancement.
In addition to the continuous expansion of fuel substitution, raw material substitution is also further enlarging the comprehensive benefits of "unconventional resources". Donghua Science and Technology actively explores the application path of replacing some traditional raw materials with cheap industrial waste residues, reduces the proportion of raw materials such as fly ash, and continuously improves the comprehensive utilization level of cheap resources while achieving quality, cost reduction and efficiency.
On the basis of promoting the substitution of raw materials, the company synchronously optimizes the allocation of raw materials, improves the stability of cement strength by selecting high-quality mineral powder, enhances the supporting capacity of product quality, and gradually improves the output of grinders and reduces the level of unit power consumption by experimenting with different amounts of grinding AIDS and changing the location of grinding AIDS. To achieve the coordinated promotion of raw material substitution, quality stability and system efficiency improvement.
To make "technological transformation" a sharp tool
for reducing consumption, we must first sharpen our tools. With the available alternative fuels and the stable equipment system, the index optimization and coal consumption reduction can be realized.
Focusing on the improvement of operation stability of clinker production system, Donghua Science and Technology insists on taking equipment technological transformation as an important grasp of consumption reduction, and continuously promotes the optimization and upgrading of key systems. Heat in clinker production is closely related to coal consumption. Preheater system is an important part of clinker burning thermal system, and its operation state is directly related to the system thermal efficiency and coal consumption level.
"We carry out air leakage investigation and treatment on the eight-layer pipeline system of the first-line preheater, effectively eliminate the problem of external air leakage, use the maintenance window period, add air gun devices at the position where the feeding pipe is easy to block, work in a two-pronged manner, effectively improve the thermal efficiency and operation stability of the preheater system, and reduce the additional coal consumption caused by system fluctuations." Tian Haiyang, deputy director of the company's clinker division and director of the firing workshop, said.
Focusing on the problem of large system resistance, the company also implemented the preheater resistance reduction renovation project, which effectively improved the ventilation conditions of the system by optimizing the intake structure of the cyclone, adjusting the wind speed of key pipelines and expanding the capacity of the decomposition furnace. After a series of preheater retrofits, the standard coal consumption is reduced by more than 0.3 kg/t and the power consumption is reduced by 0.4 kWh/t, which provides important technical support for the continuous promotion of energy saving and consumption reduction.
At the same time, the company also repaired and optimized the first-line kiln head, kiln tail rotor scale rotor and upper and lower sealing plates of clinker production line to further improve the stability of pulverized coal feeding, reduce the increase of coal consumption caused by system fluctuation, and create good conditions for stable combustion efficiency.
"Optimization is endless.". We are constantly looking for better transformation ideas and more advanced technology to help equipment improve efficiency and speed up, better serve production, so that coal consumption is no longer the "hard bone" that restricts production costs. Zhang Bing, deputy general manager of the company and Minister of clinker business, said.
The transformation of "system consumption reduction" into "development advantage"
opens up the space for cost reduction, and the system optimization and transformation stabilizes the operation foundation, so the sustainable consumption reduction ability formed by the coordinated promotion of "double replacement" is accelerating the transformation into the competitive advantage of Donghua's scientific and technological development.
In the process of promoting the substitution of raw materials and fuel materials and the optimization and transformation of the system, Donghua Science and Technology has not only realized the continuous decline of the unit coal consumption index, but also promoted the transformation of clinker production from "relying on a single energy structure" to "multiple substitution and synergistic support", from "phased technological transformation and consumption reduction" to "systematic operation and consumption reduction". A stable, replicable and sustainable energy-saving and consumption-reducing operation mode has been gradually formed, which provides a solid guarantee for the long-term stable operation of the production system.
At the same time, the continuous promotion of the "double substitution" work has also significantly enhanced the ability of enterprises to cope with fluctuations in the energy market. Faced with the cost pressure brought by the cyclical change of coal price, Donghua Science and Technology has continuously expanded the utilization space of alternative resources and strengthened the stable operation ability of the system, so as to enrich the means of production cost adjustment and enhance the flexibility of operation, effectively enhancing the ability of enterprises to resist market risks and the initiative of operation.
In the expansion of alternative materials, the advantages of internal synergy have gradually emerged. "Some alternative raw fuel materials can achieve internal synergy'win-win ', Qixiang Tengda's production of'waste' wet fly ash, is an important alternative fuel we use in large quantities." Zhang Bing said that this can bring more than one million yuan of economic benefits to both sides.
Cost reduction is only a phased achievement, and the deeper change lies in the coordinated promotion of raw material substitution and system optimization, which is promoting the continuous improvement of the comprehensive utilization capacity of resources, continuously optimizing the performance of environmental protection indicators while achieving cost pressure reduction, and realizing the coordinated improvement of economic and ecological benefits. To explore a sustainable development path for the green low-carbon transformation of enterprises.
"We cooperate with relevant companies to promote the co-disposal of solid hazardous waste as an important path for comprehensive utilization of resources, and now the procedures for the construction of cement kiln solid hazardous waste extraction and fuel substitution (Phase I) project have been completed and are progressing in an orderly manner." Sun Caizhao, business director of the company's Ministry of Ecology and Environmental Protection, said.
From expanding the utilization space of alternative resources, to continuously optimizing the system operation ability, to continuously enhancing the cost control ability, Donghua Science and Technology is accelerating the transformation of energy saving and consumption reduction from technical measures to management ability, from index improvement to development advantage, so as to continuously extend the benefit growth line of the "substitute" article and realize the "substitute". Continuous accumulation of new momentum and space for high-quality development of enterprises.
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