Reduce costs and increase efficiency
The war drums urge us on, and the sword of cost reduction and efficiency improvement is drawn! All units of Hebei Xinda Steel Group Co., Ltd. have integrated "cost reduction" throughout the entire production chain, aiming for the goal of "ultimate cost, ultimate efficiency, and ultimate benefit", and are fully committed to stimulating the vitality, drive and creativity of the enterprise. The ironmaking plant responded promptly to the call, taking lean management as the engine, locking the improvement of the coal ratio target as the core battlefield, driving management innovation with systematic thinking, and continuously setting new records in production indicators.
Through this series of scientific, rigorous and interlinked cost reduction measures, in the second quarter, the average coal ratio of the ironmaking plant exceeded the planned target by 5.8kg, and the single furnace coal ratio index exceeded the plan by 11.8kg/t. Not only was the monthly task exceeded, but also the historical high was broken for three consecutive months. In a single month, the good coal ratio index of a single furnace achieved a profit of over 700,000 yuan, and the coal ratio breakthrough achieved a profit of over 2 million yuan, injecting strong impetus into the enterprise to reduce production costs and enhance market competitiveness.
Strong control over front-end extension
The stable operation of the blast furnace is guaranteed
Take the system as the guideline and focus on tackling tough problems. The ironmaking plant has established an efficient management system for the coal ratio breakthrough. It has selected experienced factory-level cadres to serve as project leaders and formed cross-departmental special task forces to intensively tackle the technical bottlenecks and coordination difficulties encountered in the process of improving the coal ratio. Peng Dingchang of the ironmaking plant leads his team to the production frontline every day to keep abreast of the production dynamics in real time. In response to situations such as fluctuations in raw materials and abnormal production operations, comprehensive analysis and discussion should be organized and carried out to formulate solutions and ensure the efficient and smooth production process.
The fine materials are fed into the furnace, and the source is strictly controlled. The ironmaking plant has established a close linkage mechanism with the supply department, optimized the procurement strategy, and introduced high-quality coke resources to ensure the quality of coke from the source. After testing, the strength indicators and reactivity of the newly purchased coke are significantly better than those of previous periods, laying a solid foundation for the stable operation of the blast furnace.
Precise control to stabilize the "food supply". The ironmaking plant implements full-process monitoring of the entire coke feeding system. According to the quality characteristics of coke, it is classified into two categories, A and B, for management, and a detailed proportioning plan is implemented to ensure that coke of different qualities is precisely fed into the furnace in proportion. At the same time, a strict feedstock review mechanism should be established to eliminate feedstock confusion and ensure a stable supply of "rations" for blast furnaces.
Refine the process and deeply explore its potential
Efficiency improvement adds impetus
High-quality materials are fed into the furnace to ensure good ventilation. Focusing on the screening process of the ore tank, the screening equipment was upgraded and renovated. By strictly controlling the screening rate at 25kg/s, and at the same time, coke drying was put into use, with the drying temperature reaching 80-100℃, and the feeding of powder-containing materials into the furnace was controlled. In addition, strictly implement the daily material inspection mechanism by the foreman and the foreman, strictly control the amount of powder fed into the furnace within the standard range, effectively improve the air permeability inside the furnace, and create favorable conditions for the smooth operation of the blast furnace.
Data-driven, flux optimization. The ironmaking plant, in collaboration with departments such as the Quality and Measurement Department, has made concerted efforts to drive production decisions with data. By establishing a real-time monitoring system for slag composition and adjusting the operating parameters in a timely manner based on the test results, the magnesium-aluminum ratio of the slag was controlled within the range of more than 0.6, significantly improving the fluidity of molten iron, reducing the resistance inside the furnace, and lowering energy consumption.
Hot air precise control, combustion efficiency enhanced. For the burning process of the hot blast stove, special technical renovations were carried out. By optimizing the burner structure and improving the control system, the full closure operation of the blast furnace's air mixing valve was achieved. Based on the automatic combustion furnace, manual combustion is carried out according to the oxygen content, taking into account the temperature of the top of the hot blast stove and the flue. Both the initial and final temperatures of the supply air are controlled to create an ideal environment for the complete combustion of pulverized coal.
Stable airflow and oxygen-enriched efficiency improvement. Deeply optimize the gas flow distribution inside the furnace, and use advanced gas flow monitoring equipment to grasp the changing patterns of the central and edge gas flows in real time. By precisely adjusting the fabric matrix and blower parameters, a dynamic balance between the two airflows is achieved, significantly enhancing the stability of the furnace condition. At the same time, strictly control the oxygen enrichment rate, add an automatic oxygen enrichment flow regulation device, and stably keep the oxygen enrichment rate above 8%, with an hourly oxygen enrichment of about 24,000 cubic meters, significantly improving the combustion efficiency of pulverized coal.
Auxiliary efficiency enhancement, equipment protection. Optimize the raw material ratio, increase the proportion of anthracite used, and improve the pulverizing process to enhance the fineness of coal powder, thereby increasing the contact area between coal powder and air and ensuring more complete combustion. Establish a "special protection" mechanism for coal injection and blast furnace air supply systems, increase the frequency of equipment inspections, and apply advanced technologies such as infrared temperature measurement and vibration monitoring to detect and eliminate potential fault hazards in advance, fully leverage the operational performance of the equipment, and create convenient conditions for production.
Sweat nourishes harvest, and hard work determines progress. Hebei Xinda Steel Group Co., Ltd. will adhere to precise policy implementation, pool wisdom and strength, and work together with one heart. With the awareness that "a single leaf changing color can tell the autumn of the world", it will enhance understanding and strengthen responsibility, focus on key areas and strengthen control, break down goals and ensure their implementation. It will forge core advantages by optimizing production indicators and deeply lay the foundation for efficiency improvement by strengthening cost control, striving for meticulous and perfect cost reduction and efficiency improvement. We will enhance efficiency, optimize structure, enforce strict management and explore innovation. With persistent efforts, we will engrave the answer sheet of The Times. After climbing one mountain, we will climb another; after crossing one gully, we will leap over another. We are determined to promote the company's green and high-quality development path steadily and far!
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