Remarkable achievements in carbide consumption of Jinwei coal

Since Jining Jinwei Coal Power Co., Ltd. started the second phase, the consumption of PVC calcium carbide has been high, which is an important reason for the decrease of enterprise profit and loss. In view of this situation, leaders of the company attach great importance to it, and set up a research group to reduce calcium carbide consumption with division and cooperation of production, technology, supply, equipment and quality inspection departments, analyze the reasons for the rise of calcium carbide consumption, clarify the direction of research, and make breakthroughs in many aspects. Through strengthening the quality management of calcium carbide and the implementation of many technical reforms, many problems were overcome, and the consumption of PVC calcium carbide was significantly reduced. In the first quarter, the consumption of calcium carbide fell to 1.480 from 1.593 in the same period last year, and a new breakthrough was made in April. The consumption of calcium carbide was only 1.435, which means that for each ton of PVC produced, 158kg of calcium carbide was used less, and the cost of calcium carbide was saved by 500 yuan. To maintain this level of consumption, the annual savings are in billions.

With the continuous release of the second stage capacity of chemical industry, the high consumption of calcium carbide has seriously restricted the development of Jinwei coal power. Therefore, since last year, Jinwei coal and Power Co., Ltd. has taken reducing the unit consumption of calcium carbide as the key work of double reform and double promotion and benchmarking management activities. It has held special meetings for many times to arrange the deployment, and organized members of the research team to visit and study in Tancheng yangcoal Hengtong group. Through on-site investigation and exchange, it has found out the problems and deficiencies in calcium carbide management. After full discussion, the following three links are determined: to ensure the quality of calcium carbide, quality inspection analysis control and process equipment transformation. In the quality management of calcium carbide, the material supply department of the company strictly controls the access to the factory. It has changed the previous method of waiting for goods to be received, and sent a salesman to the carbide manufacturer to supervise the loading and departure. The evaluation system of calcium carbide suppliers has been initially established to reduce the evaluation of suppliers with problems and reduce their supply volume; new suppliers in Inner Mongolia, Ningxia and other places have been actively developed to achieve certain initiative in the quality and price of calcium carbide. In addition, after the establishment of Lutai logistics company, it also played a positive supporting role in the quality, price and transportation of calcium carbide. The chemical warehouse and acetylene section of the chemical branch company strictly control the unloading. Arrange the carbide administrator and acetylene section manager of the chemical warehouse to get on the train to check the appearance of the carbide, and focus on the color of the appearance of the carbide, whether there are the phenomena of adulteration, raw carbide and serious pulverization. In the first quarter, 63.9 tons of calcium carbide were discounted due to the serious raw material and pulverization of calcium carbide, and the problem of Xuzhou Sanjie company adulterating coal gangue into calcium carbide was punished. The quality inspection center of chemical branch strictly controls the inspection. After passing the visual inspection, all carbide shall be unloaded for sampling. In the past, only the upper sample can be taken from the upper sample, and the quality of the lower calcium carbide cannot be determined. Now after unloading, sampling is more random and representative. In addition, the activity areas of suppliers, sampling personnel and quality inspectors shall be separated, and the calcium carbide samples shall be randomly numbered to avoid human fraud. The company's business management, production, audit and other departments send personnel to supervise the whole process of carbide sampling, sample delivery and analysis every day. Multi level management and multi-level supervision effectively ensure the fairness, fairness and accuracy of the analysis data. Through the quality management of calcium carbide, a total of 55735.63 tons of calcium carbide were put into storage in the first quarter, 704.47 tons of unqualified calcium carbide were discounted, and the average gas output of calcium carbide was 296.2l/kg, which made a good precondition for the reduction of calcium carbide consumption. In terms of process optimization and equipment transformation, each process from carbide feeding to PVC resin packaging and each intermediate product are checked one by one, and the discharge point, leakage point and material running point affecting carbide consumption are guaranteed to the work section and the responsibility is personal. 12 technical reforms have been carried out successively to improve the utilization efficiency of calcium carbide and reduce the discharge of materials. Good results have been achieved: the transformation of calcium carbide dust removal fan, the improvement of the recovery rate of calcium carbide dust and the recovery and reuse of calcium carbide dust. In addition to the transformation of iron, the damage of iron bars and iron bars in calcium carbide to the conveyor belt, generator and other equipment is reduced, the number of maintenance is reduced, and the replacement and discharge of acetylene is reduced. The addition of carbide unloading trolley increases the feeding amount by 30%, reduces the feeding times and reduces the acetylene discharge during replacement. In the polymerization section, the coating kettle system of the polymerization kettle was reformed. The cleaning cycle was increased from the original 50 kettles to the current 120-150 kettles, which improved the utilization efficiency of the polymerization kettle and reduced the loss of vinyl chloride due to the replacement of the cleaning kettle. Through strengthening the management of calcium carbide quality, quality inspection and analysis, and the transformation of process equipment, the consumption of calcium carbide decreased significantly, and the production cost of PVC further reduced. The development of a series of work conforms to the general idea of Jinwei coal power's "three improvements and one reduction" work, and is also the highlight of double reform and double promotion and benchmarking management activities, laying a solid foundation for the release of production capacity in the second half of the year and turning losses into profits. (key words: calcium carbide)