Since the clarion of the Group's cost reduction and efficiency improvement action sounded, the companies have responded quickly and actively, held several "cost reduction and efficiency improvement" seminars, conducted exchanges and discussions on various promotion and implementation plans, and set up special working groups to systematically plan and organize the implementation of various work measures to reduce cost and improve efficiency. Each branch factory and production unit closely combined with the actual production, innovative ideas, lean management, starting from the subtle point, the cost reduction and efficiency throughout the work, through optimizing the production process, strengthening equipment maintenance, improving the skill level of employees and a series of measures, in-depth tap the potential of cost reduction, quality and efficiency.
It is the key work to improve product quality, reduce alloy consumption and increase metal yield in steelmaking process, and also the core to reduce the cost of steelmaking process. At the same time, improving the converter one down rate is also a direct way to improve the production efficiency of the converter, and can effectively reduce the consumption of refractory materials, which is conducive to the improvement of the age of the converter. After sorting out the key data of the steel mill of Hebei Rongxin Iron and Steel Co., LTD., it is found that the mean value of solvent material is relatively excellent in the surrounding steel mills, but the consumption of alloy and steel material is high. Through data comparison, it is found that the steel carbon and one pour rate of the converter are obviously low. In order to reduce consumption and save costs, the steelmaking plant has set up a research group to carry out research on the topic of improving the converter one-down rate. The group, led by factory director Liu Guojun, developed a detailed activity plan and set a target of 80%.
The research team analyzed the reasons for the low conversion rate of converter from five aspects of the man-machine material process, and analyzed nine factors such as high silicon in hot metal, small furnace volume ratio and unstable iron consumption control. After the field inspection of nine factors, six non-main reasons were excluded one by one. Finally, it is determined that the main reasons affecting the converter one-down rate are poor operation skills, small furnace capacity ratio and non-standard operation methods.
The research team adheres to the belief of "learning with problems, returning with results, and working with methods" to find methods and solve problems. In view of the poor operation skills of personnel, Yao Yongqiang, deputy director of production technology, made training courseware on basic knowledge of converter, and organized all furnace captains and shakers to conduct basic knowledge training on spatter control and dephosphorization. Organize the staff of three shifts to resume the work after work, and the furnace foreman and the furnace shaker will come up with the best furnace operation in the class and share the successful experience; Take out the worst furnace to analyze the existing problems, and other personnel participate in the analysis to learn the successful experience and failure lessons; The key indicators of the converter are set up in the conference room and updated every day to facilitate all operators to compare advanced, find deficiencies, and strive to improve.
In response to the problem of small furnace capacity ratio, the research team decided to control the total load of the converter according to the theoretical calculation and combined with the loading situation of the converter with the same tonnage around the furnace capacity ratio of 0.96, and formulated the "Regulations on the Implementation of standard loading System of the converter", which was sent to the hands of employees for in-depth learning.
In view of the problem of non-standard operation methods, the operation standards and operation instructions of the converter have been revised comprehensively. The furnace material data control table and gun position control table are equipped on site to provide reference for operators and facilitate unified operation; Also through the implementation of training activities, on-site monitoring and other methods, urge operators to strictly implement standardized operations.
According to statistics, by strengthening and promoting the above improvement measures, on the basis of keeping the dephosphorization rate of the converter and the carbon at the end point controllable, the spatter rate of the converter is greatly reduced. Due to the substantial decrease in the spatter rate of the converter, the influence of charging pressure spraying on the flame is greatly reduced, and the growth rate of slag deposit in the furnace mouth is also slowed down, which is more convenient for the furnace mouth cleaning and ensures that the operator can observe the flame change. Through the improvement of these processes, the converter one-down rate has been significantly improved, and has been increased to about 85%.
By improving the converter one-down rate, the three indicators of steel material consumption, alloy consumption and carburizer consumption have been improved, and it is estimated that the annual benefit is about 22,476,800 yuan.
Only when the screw is tightened can it be vigorous, and only when the responsibility is compacted can it be effective. All Xin master should seize the opportunity, take advantage of the momentum, work with one heart and one mind, pragmatic action, apply the mind to the work, apply the strength to the implementation, apply the energy to solve the problem, dig the potential inward, and compete for the market outwards; Focus on management, reduce costs, continue to optimize cost reduction and efficiency measures, and maximize the potential of management and control. On the road to continuous improvement, we need to finish the beginning, do good, do good, do not succeed, never quit the mission, and help Xinda this steel giant ship sail away!
Email
Email