On April 29th, 2009, the first domestic third-generation nuclear power main pipeline hot elbow was successfully smelted in our company with AP 1000 electroslag ingot, with a weight of 73 tons per elbow. This is a major breakthrough in the field of raw material smelting of China's nuclear power main pipeline, and the products have been mass-produced, laying the foundation for the company to further enter the field of nuclear power equipment manufacturing. In 2009, the successful development of large tee forgings in thermal power plants will play a positive role in import substitution. The company's independent innovation advantage has become the key to its core competitiveness.
At present, the company has established long-term cooperative relations with Metal Research Institute of Chinese Academy of Sciences, University of Science and Technology Beijing, Beijing Petroleum University, Yanshan University, Zhejiang University, and Iron and Steel Research Institute. In the future, the company will continue to strengthen Industry-University-Research's technical cooperation in various ways, speed up the establishment of academician workstations and postdoctoral workstations, establish scientific and technological strategic alliances with well-known scientific research institutions and universities at home and abroad, and continuously enhance the core competitiveness of enterprises. Large forging billet smelting equipment: At present, the company has advanced domestic special steel smelting equipment such as 40t high-power electric arc furnace, 50t VD/VOD refining furnace and 50t LF refining furnace, and electroslag steel smelting equipment such as 40t, 30t and 20t numerical control electroslag remelting furnaces. 100 ton high-power electric arc furnace, 150 ton VOD refining furnace and 150 ton LF refining furnace matched with 12000 ton oil press are under construction and will be put into use soon.
Forging equipment: The company has 3 150t and 1.250t oil-operated free forging presses and their supporting 80t forging cranes, 100t and 50t lifting cranes, natural gas heating furnaces and post-forging heat treatment furnaces, all of which adopt German control technology, and can realize automatic ignition, automatic adjustment and automatic temperature control.
The company is implementing the self-developed12000t oil-driven free forging press forging project in the factory area of a large forging production base, and has12000t oil press, 400t.m manipulator, 550t/300t forging crane and other heavy equipment. The project has now entered the debugging stage, with a maximum forging capacity of 450 tons of steel ingots and a maximum forging tonnage of 350 tons of forgings.
Heat treatment equipment: the company has fully automatic numerical control 3.6× 18m, 2.6×30m well-type natural gas furnaces, 3x20m hood furnaces, 6x 15x5m, 7x 10x5m trolley-type natural gas furnaces, 25MN numerical control straightening hydraulic press, large-scale dual-frequency quenching machine tools, horizontal spray quenching machine tools, etc.
At present, the heavy-duty heat treatment workshop project of the company's large forging production base is equipped with heavy equipment such as φ2700mm×30000mm well furnace, 3,000t straightener and 200t/50t quenching crane. The project has now entered the debugging stage, which will further enhance the company's heavy equipment manufacturing capacity. Advantages of industrial chain: the company has now formed a circular economy industrial chain integrating scrap steel, steel chip acquisition, forging blank preparation, forging, heat treatment, mechanical processing and inspection. The main production equipment has reached the leading level in China, which fundamentally ensures the close connection and rapid circulation between the production processes such as smelting, forging and heat treatment of leading products, and saves energy and transportation costs. Scrap steel and steel chips produced during forging and machining can be remelted into high-quality special steel, which can be reused as raw materials, realizing the recycling of waste resources and further reducing the production cost; The steam generated by waste heat recovery in smelting process is used in vacuum casting process, which solves the problem of smelting steam recovery; The waste heat generated in the forging process is recycled, which further saves energy and reduces production cost. At the same time, with the continuous innovation of production technology, the production cost is further reduced. The advantage of industry consolidation not only improves the gross profit margin of the company's products and the company's ability to resist risks, but also ensures the supply and quality of raw materials.
Technical and technological advantages: the company's forging products are mainly shaft, tube and cylinder forgings. The company has a number of proprietary technologies, especially in the production of wind power spindle and pipe mold products, with obvious technical and technological advantages. The large-diameter deep-hole nesting technology of the company greatly improves the material utilization rate of the pipe molds produced by the company and obtains a profit rate higher than the market average. In the forming process of fan spindle, and in the forging process of some special direct-drive spindles, the company pioneered the forging process combining free forging and tire die forging. Compared with the traditional process, the new process uses a special die to forge large holes and a special mandrel to lengthen them, which changes the shortcomings of the traditional forging method, such as high heat, high energy consumption, cutting off fiber flow and unsuitable internal quality.
On the premise of ensuring product quality, realize consumption reduction and energy saving. In addition, the company's ultra-high pressure forging process for large-diameter ultra-thick-walled seamless steel pipes and the all-fiber free forging technology for slender tube forgings make the company ahead of its peers in the process and technology of tube forgings; P9 1 large tee forgings for thermal power stations and special electroslag ingots for nuclear power main pipelines developed by the company are high-tech products with high added value.
Management advantages: The company's main management personnel have more than 65,438+00 years working experience in forging industry, strong professional level and rich enterprise management ability, especially in employee performance appraisal, departmental cooperation, cost control and encouraging innovation. The company has formed a good management system, which has been effectively implemented in the process of operation and management.
Based on the advantages of industrial chain, technology, technology and management, the company has outstanding performance in cost control and strong profitability. At present, the company's leading product cost is at a low level in the same industry at home and abroad, with outstanding cost competitive advantage and strong profitability. During the reporting period, the average gross profit margin of fan spindle reached 45.55%, that of pipe mould reached 47.3 1%, that of other forgings reached 35.34%, and that of main business reached 42.45%. Large forgings have the characteristics of many varieties, specifications and small batch. Manufacturing high-quality large forgings requires very professional production experience, including equipment use, site management and long-term technical accumulation. Users usually have strict qualification certification for products. If they can meet the quality requirements of users steadily and continuously, because of the high cost of changing suppliers, users can easily reach a long-term and stable strategic cooperative relationship with large forging production enterprises, thus restricting new entrants.
Through years of independent innovation and centralized management, the company's main products have occupied a large market share, and the company has established a high market position in the industry and established a long-term strategic partnership with customers.
As the largest wind power spindle manufacturer in China, its main users include Danish Vestas (ranked first in the world in 2009), American GE Wind Energy Company (ranked second in the world in 2009), Sinovel Wind Power (ranked third in the world in 2009), Spanish Gomesa (ranked sixth in the world in 2009), Dongfang Electric (ranked seventh in the world in 2009) and Suzhou, India.
As the largest pipe mold manufacturer in China, the company's main customers in the domestic market are: Xinxing Cast Pipe, Dalian Wantong, Saint-Gobain (Xuzhou), Xuzhou Everbright Cast Pipe Co., Ltd. and other famous domestic cast pipe manufacturers. At the same time, the company's pipe mould products are exported to India (India Power and Steel Company, India Electric Heating Company, India KDU Company and India GDU Company), South Korea (South Korea Xin 'an Company) and Malaysia (Yongda Ductile Iron Pipe Co., Ltd.), and are sold to Egypt, Iran, Saudi Arabia, Switzerland, Turkey and other Asian, European and African countries through Feipai trade. Large forgings are the key basic parts necessary for major national technical equipment and major engineering construction, and the manufacturing capacity and level of large forgings directly determine the manufacturing capacity and overall level of China's equipment industry. However, there is still a big gap between the energy level of large forgings in China and that of foreign countries, and some large and key forgings still need to be imported.
On May 12, 2009, the State Council promulgated the Adjustment and Revitalization Plan of Equipment Manufacturing Industry, which clearly stated: guide specialized parts manufacturers to develop in the direction of "specialization, precision and specialization" and reverse the situation that basic supporting products mainly rely on imports. Focus on the development of large-scale nuclear power equipment castings and forgings, castings and forgings of million kilowatts supercritical/ultra-supercritical thermal power units, castings and forgings of large-scale Francis turbine units above 700,000 kilowatts, castings and forgings of heavy containers in petrochemical and coal chemical industries, castings and forgings of continuous cold and hot rolling mills, forgings of large marine crankshafts and propeller shafts, and forgings of large bearing rings. Increase investment in key infrastructure supporting enterprises and guide private capital and foreign investment in infrastructure.
Parts, processing AIDS and other fields, the development of a number of high starting point, large-scale, specialized enterprises, improve the industrial supporting system. After the expiration of the value-added tax policy for castings, forgings, molds and CNC machine tools, we will study and formulate new tax support policies, adjust the scope of application of the policies, and guide the development of high-tech and high value-added products.
The company's leading products are in line with the national industrial policy and have received strong support from the state. Forgings and pipe molds all enjoy the value-added tax policy, and export products such as pipe molds and fan spindles enjoy the tax-free policy.