[China Glass Network] Float glass enterprises are large energy consumers. It is a great trend to save energy and reduce consumption, reduce costs, improve the market competitiveness of enterprises, reduce environmental pollution and alleviate energy shortages. Especially in recent years, the increasing number of float glass production lines in the country has made the competition in the glass industry increasingly fierce. The cost reduction, energy saving and efficiency increase are the problems that all glass manufacturers must face. In order to be able to occupy a place in the industry and start their own brand, many companies have begun to implement energy-saving and efficiency-enhancing measures in the production process, and explore ways to increase efficiency in glass production process control.
The energy-saving and efficiency improvement of glass enterprises is a long-term task. The domestic and foreign technicians actively carry out research, such as the optimization of furnace structure design, oxyfuel combustion, 0# small furnace oxy-fuel combustion and other technologies, and some manufacturers have adopted some advanced The measures have achieved certain results. However, for a variety of reasons, some advanced technologies have not been universally applied. For the production line that has already been operated, in order to ensure energy-saving and efficiency-enhancing in ensuring a safe and stable production process, careful selection is also required. In the whole production process, how can the fuel consumption cost reach a low level, whether the waste heat in the production process can be rationally utilized, and whether the existing equipment can be transformed to achieve energy-saving effect is practical and easy to implement and solve. problem.
Based on the theoretical knowledge, combined with the production practice, this paper elaborates on the measures that have been implemented and achieved obvious effects, such as the rational selection of fuel, the improvement of packaging technology and the utilization of waste heat.
1. Replacement of fuel 1.1, fuel use
Fuel is one of the key elements in the production of float glass. Fuel costs account for more than 40% of the total glass cost, and the proportion is rising. The excessive cost of fuel has reduced the profitable space of enterprises and has become a major problem that restricts the bottleneck of glass enterprises. Therefore, the lower-priced fuel varieties have become the target of choice for glass manufacturers.
In the float glass production line, heavy oil, coal tar, natural gas, producer gas, etc. are generally used as fuel. In order to reduce fuel costs, some research institutes continue to research new fuels as substitutes, and some domestic glass companies are actively looking for and using cheap alternative fuels. In recent years, many glass manufacturers have gradually changed from burning heavy oil to burning coal tar, coal tar to burning petroleum coke, and even manufacturers of petroleum coke and pulverized coal. The replacement of fuel to a certain extent saves a part of the fuel cost for the enterprise, reduces the total cost of float glass production, and makes a great contribution to the development of the enterprise. Glass manufacturers can choose the right fuel to reduce costs according to their own glass quality. It can be said that fuel replacement is an effective way to save costs.
1.2, an example of fuel replacement
In order to adapt to the severe market situation, a company keeps abreast of the information in the industry in terms of fuel use and looks for ways to reduce costs. In 2006, in the face of the rising trend of heavy oil prices, we kept abreast of the market and successfully converted the two production lines from heavy oil to coal tar. The two lines reduced the cost by more than 2 million yuan per month. In 2009, some small furnaces in the first and second line of the float method successfully replaced coal tar by natural gas. In 2011, the float line was changed from coal tar to full kiln fired natural gas, giving companies more choices in the complex and volatile fuel market, while providing a basis for melting high quality glass. In 2009, we used a three-month period to increase a set of petroleum coke powder system. In August, petroleum coke successfully replaced coal tar. The two lines used petroleum coke powder, the melting was stable, the product quality was normal, and the monthly fuel recovery cost was over 5 million yuan. . The company's choice of fuel, rapid operation, good timing, so it has achieved significant results in reducing costs.
2. Improvement of float glass packaging process 2.1. Status of float glass packaging
The packaging of float glass is usually in the form of packaging such as pallets and wooden boxes. Because customers need to provide deposits to manufacturers, and the capital turnover period is long, the management and maintenance costs are high, long-distance transportation and export are restricted, time-consuming and laborious, and the use of container packaging, there are many problems that make it limited to use. About 20% of the total market. Wooden box packaging is the packaging form used by most manufacturers when it is supplied, accounting for about 80% of the total market. Wooden box 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, it costs more, in addition to the cost of wooden boxes. Some packaging steel strips, accessories and labor costs; third, there are many links, easy to appear quality problems, the entire packaging process has buckle, packaging, nail boxes and other processes. Improper operation of all processes can easily damage the glass, such as glass bumps, nail damage, etc. In addition, it can cause the strength of the wooden box to decrease and the stability is poor.
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, industry professionals have taken more measures on glass packaging, such as: optimizing the structure of wooden boxes, selecting wood materials and filling materials, selecting nails reasonably, paying attention to the reinforcement of key parts, or using metal (entry). The metal "provided by the industry encyclopedia" skeleton, effectively increase the strength and stability of the wooden box, in order to achieve a reasonable saving of wood. These measures are still being further improved and explored. Float glass die packaging is a good way to solve the current problems. At present, some manufacturers have implemented the glass bare-packing process.
2.2. Introduction to the improvement of bare-metal process
A company's float glass packaging was originally mainly packaged in wooden cases, plus some packaging accessories, the cost is higher. In order to reduce costs and further improve the quality of packaging, the company has been carefully considering all aspects of production, loading, storage, transportation and sales since 2006, and has been groping for technical personnel to inspect the glass manufacturers that have implemented the bare-packing process. After a lot of investigation and demonstration, it was determined that the wooden box packaging was cancelled and the technical scheme of bare glass was implemented. In order to ensure the smooth implementation of the bare-packing process, the company's technicians made a special tooling spreader, and constantly researched and improved. In 2008, the plastic packaging was removed on the basis of removing the wooden box, and the naked clothing was completely implemented. In the implementation process of the bare-packing process, the gradual transition from thick plate bare-fabrication to thin-plate bare-packing, at present, all of the 3~15mm glass is bare-faced. Of course, depending on the customer's needs, some special requirements of the glass need to be wrapped in plastic sheets.
2.3. The effect and benefits of implementing the bare-packing process
(1) The bare glass process of float glass has completely changed the situation of wooden box packaging that flat glass has been used for many years, and prevented the glass damage caused by the phenomenon of nail penetration and nail leakage caused by wooden box packaging. The storage is simpler and more efficient.
(2) The economic benefits are significant. The nakedness process after removing the wooden box and the plastic sheet greatly reduces the production cost. Each package saves wooden boxes, iron waists, steel nails, etc. (the term "fixed" is provided by the industry encyclopedia). The cost of accessories for wooden boxes is about 360 yuan, and each package saves about 1.4kg (10,000 yuan/t) of plastic cloth. Judging from the bare glass of 3 lines, the monthly bare glass volume is 16,000 bales, and the annual economic benefit is more than 70 million yuan.
(3) Significant social benefits. Each wooden box consumes about 0.16m3 of wood. According to the 3 float production lines, it produces 16,000 pieces of bare glass every month. It saves more than 30,000m3 of wood every year, which greatly reduces the consumption of wood. It should be said that the glass bare-packing process is a revolution in glass packaging and has extremely significant practical significance for protecting the ecological environment.
(4) Reduced the labor intensity of the on-site staff and improved the working environment. From the customer feedback situation, while customers enjoy the price benefits brought by bare-packing, it greatly reduces the customer's back-transport and use process, improves the customer's operational safety, reduces damage, and is well received by customers. .
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