Energy saving and efficiency increasing transforma

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Energy saving and efficiency improving measures for float glass enterprises are energy intensive. Saving energy, reducing consumption, reducing costs, improving the market competitiveness of enterprises, reducing environmental pollution and alleviating energy shortages are the general trend, which is of great significance. Especially in recent years, the increasing number of national float glass production lines has made the competition in the glass industry increasingly fierce. Reducing costs, saving energy and increasing efficiency are the problems that all glass manufacturers must face. In order to occupy a place in the industry and establish their own brands, many enterprises have begun to implement energy-saving and efficiency increasing measures in the production process, and explore efficiency increasing measures in the control of glass production process

energy saving and efficiency increase in glass enterprises is a long-term task. Domestic and foreign technicians actively carry out research, such as using technologies such as optimizing furnace structure design, oxygen enriched combustion, 0# small furnace full oxygen combustion and melting aid. Some manufacturers have also taken some advanced measures and achieved certain results. However, due to various reasons, some advanced technologies have not been widely used. For the production line that has been running, we need to choose carefully if we want to take measures to save energy and increase efficiency in the process of ensuring safe and stable production. In the whole production process, how to achieve a low level of fuel consumption cost, whether the waste heat in the production process can be reasonably utilized, and whether the existing equipment can be transformed to achieve energy-saving effects are all practical and easy to implement and solve problems

based on theoretical knowledge and combined with production practice, this paper expounds the measures that have been implemented and achieved remarkable results, such as the reasonable selection of fuel, the improvement of packaging technology and the rational utilization of waste heat

1. Fuel substitution

1. 1. Fuel usage

fuel is one of the key elements in the production of float glass. The fuel cost accounts for more than 40% of the whole glass cost, and the proportion is rising. The high fuel cost has compressed the profit space of enterprises, which has become a major problem restricting the development of glass enterprises. Therefore, the fuel varieties with lower prices have become the selection targets of glass manufacturers

in float glass production lines, heavy oil, coal tar, natural gas, producer gas, etc. are generally used as fuels. In order to reduce the cost of fuel, some scientific research institutes continue to study new fuels as substitutes, and some domestic glass enterprises are also actively looking for and using cheap alternative fuels. In recent years, many glass manufacturers have gradually changed from heavy oil to coal tar, coal tar to petroleum coke, and even petroleum coke and pulverized coal are burned together. The substitution of fuel has saved part of the fuel cost for the enterprise to a certain extent, reduced the total cost of float glass production, and made a great contribution to the development of the enterprise. Glass manufacturers can choose appropriate fuels to reduce costs according to their own glass quality. It can be said that fuel substitution is an effective way to save costs

1。 2. An example of fuel substitution

in order to adapt to the severe market situation, a company timely understands the information in the industry on the use of fuel and looks for ways to reduce costs. In 2006, in the face of the rising trend of heavy oil prices, we learned the market in time, and successfully changed the two production lines from heavy oil to coal tar, reducing the cost of the two lines by more than 2 million yuan per month. In 2009, natural gas successfully replaced coal tar in some small furnaces of the first and second lines of float. In 2011, the third line of the float process was changed from coal tar to full kiln burning natural gas, giving related companies more choices in the complex and volatile fuel market, and providing a basic guarantee for melting high-quality glass. In 2009, it took three months to add a set of petroleum coke powder system. In August, petroleum coke successfully replaced coal tar. The two lines used petroleum coke powder, which has stable melting and normal product quality. The monthly fuel purchase cost was reduced by more than 5million yuan. In terms of fuel selection, the company operates quickly and has a good opportunity to cut in. Therefore, it has achieved obvious results in reducing costs

2. Improvement of float glass packaging process

2. 1. Current situation of float glass packaging

the packaging of float glass usually adopts container racks and wooden cases. Because customers need to provide a deposit to the manufacturer, and the capital turnover cycle is long, the management and maintenance costs are high, the long-distance transportation and export are limited, which is time-consuming and laborious. The use of container packaging is limited by many problems, accounting for only 20% of the total market. Wooden case packaging is the packaging form used by most manufacturers when supplying goods, accounting for about 80% of the total market. Wooden case packaging accounts for a large proportion in the industry, but this packaging method also has shortcomings: first, it uses more wood and consumes a lot of forest resources; Second, the cost is high. In addition to the cost of wooden cases, there are some packaging steel strips, auxiliary materials and labor costs; Third, there are many links, which are prone to quality problems. The whole packaging process includes box fastening, packaging, box nailing and other processes. Improper operation of all processes is very likely to damage the glass, such as glass bumping, through nail damage, etc. in addition, it will also cause the strength of the wooden box to decrease, poor stability and other phenomena

in view of the above situation, improving the form of glass packaging has become one of the topics of great concern to the industry, and it is necessary to innovate and improve the glass packaging technology. In recent years, people in the industry have taken many measures for glass packaging, such as optimizing the structure of wooden cases, selecting wood materials and filling materials, reasonably selecting nails, paying attention to the reinforcement of key parts, or using metal (the entry "metal" is provided by the Encyclopedia of the industry) skeleton, effectively increasing the strength and stability of wooden cases, so as to achieve the purpose of reasonable wood conservation. These measures are still under further improvement and exploration. The packaging of float glass is a good way to solve the current problem. At present, some manufacturers have implemented the bare glass packaging process

2。 2. An example of naked packaging process improvement

the float glass packaging of a company was originally mainly packed in wooden cases, with some packaging accessories, the cost was high. In order to reduce costs and further improve packaging quality, since 2006, the company has carefully considered all aspects of production, loading, storage, transportation and marketing, and constantly explored, sending technicians to inspect glass manufacturers that have implemented bare packaging technology. After a lot of investigation and demonstration, the technical scheme of canceling wooden box packaging and implementing bare packaging on glass was determined. In order to ensure the smooth implementation of the bare packaging process, the technical personnel of the company made special tooling slings and continuously studied and improved them. In 2008, the plastic cloth packaging was also removed on the basis of removing the wooden box, and the bare packaging was completely implemented. During the implementation of the bare packaging process, it is a gradual transition from thick plate bare packaging to thin plate bare packaging. At present, all 3 ~ 15mm glasses are bare packaging. Of course, according to the needs of customers, some glasses with special requirements need plastic cloth for packaging

2。 3 as long as customers come to Jinan to see the experimental machine and the effect and benefit of the implementation of the bare packaging process

(1) the implementation of the bare packaging process for float glass has completely changed the situation of the wooden box packaging that has been used for many years for flat glass, put an end to the glass damage caused by the penetration and leakage of nails brought by the wooden box packaging, and the storage in the factory is more simple and efficient

(2) significant economic benefits. The bare packing process after removing the wooden box and plastic cloth greatly reduces the production cost. Each package saves about 360 yuan for fixing wooden cases, iron kidneys, steel nails, etc. (the entry "fixed" is provided by the industry Encyclopedia). Each package saves about 1 yuan for plastic cloth. 4kg (10000 yuan/t). According to the naked glass installation of the three lines, the amount of naked glass per month is 1. 60000 packages, with an annual economic benefit of more than 70million yuan

(3) significant social benefits. Each wooden box consumes about 0 wood. 16m3, according to 3 float production lines, 1 bare glass is produced every month. Based on the calculation of 60000 bags, more than 30000m3 of wood is saved every year, which greatly reduces the consumption of wood. It should be said that the bare glass packaging process is a revolution in glass packaging, which is of great practical significance to protect the ecological environment

(4) reduce the labor intensity of on-site workers and improve the working environment. From the feedback of customers, while customers enjoy the price benefits brought by naked packaging, it greatly reduces the transportation and use process of the customer, improves the operation safety of the customer, reduces damage, and is deeply welcomed by customers

3. Reasonable utilization of waste heat

3. 1. Current situation of waste heat utilization

in recent years, the energy policy and environmental protection policy advocated by the state require glass enterprises to take the road of low energy consumption and low pollution. The waste heat utilization, waste heat recovery and other energy-saving and consumption reduction practices of glass enterprises are in line with the national environmental protection policies such as energy conservation and emission reduction, and are one of the important ways for glass enterprises to develop circular economy

in the glass industry, there are three main methods for the utilization of waste heat: steam production by waste heat boiler, waste heat refrigeration technology, and low-temperature waste heat power generation technology. The first two technologies have been widely used, and the waste heat power generation technology is currently being promoted

3。 2. In order to continuously reduce costs and improve the market competitiveness of enterprises, a company actively understands the utilization technology of waste gas and waste heat resources in the glass industry, carefully studies the application of waste heat power generation technology in waste heat utilization technology, and deeply recognizes that waste heat power generation is not only the deep and high-level comprehensive utilization of waste gas and waste heat of glass furnaces, It is also a technology advocated and encouraged by the state for energy conservation, emission reduction and comprehensive utilization of resources. At the same time, it is one of the effective ways for enterprises to reduce costs. After fully understanding the application of waste heat power generation technology, the company decided to use the waste heat of the existing float glass production line to build a pure low-temperature waste heat power station

the waste heat power generation system built by the Institute has an investment of more than 56 million yuan, and adopts the operation mode of "three boilers and one machine", with an installed power of 6MW. Using the waste heat generated by the company's three float glass production lines, waste heat boilers are respectively set between the waste gas outlet of the regenerator at the kiln head and the chimney. The hot flue gas is heat exchanged through the water supply in the boiler and heat exchanger, and the production pressure is 2. 4MPa medium temperature sub medium pressure superheated steam with a temperature of 400 ℃, the steam produced by three boilers is gathered together through pipelines to promote the condensing steam turbine generator unit to produce electric energy, so as to realize the purpose of converting heat energy into electric energy. After heat exchange, the hot flue gas passing through the boiler is pumped to the chimney by the induced draft fan and then discharged into the atmosphere. All the power generated by the three waste heat boilers are reused for production, which can meet the power consumption of the two production lines

at the end of 2010, the construction of the waste heat power station of the company was completed, and the design mode of "three boilers and one machine" and power generation was successfully realized. Domestic brother manufacturers came to the company to visit and study in succession. The successful implementation and application of waste heat power generation has improved the corporate image and popularity, and the economic benefits are remarkable. The cost of using waste heat to generate electricity is about 0. 15 yuan/kw · h, the price of industrial electricity is about 0. 70 yuan/kw · h, the annual power generation is about 40million kW · h, and the annual economic benefit is more than 20million yuan. In addition, in winter, the circulating water waste heat generated by the turbine (the entry "turbine" is provided by the industry Encyclopedia) can be recycled to heat the office and living areas in the plant, which truly achieves comprehensive and rational utilization

4. Use of neck deep water bag

neck water bag is a liquid glass separation equipment, which is widely used in Float Furnace in China. It has the following functions: first, it blocks the unmelted powder scum or refractory in the melting section

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