Zhongzhou Branch is an alumina production enterprise affiliated to China Aluminum Corporation of China. It is an aluminum industry base prioritized in my country’s aluminum industry policy planning. In recent years, Zhongzhou Branch has firmly established the concepts of "no limit to waste elimination" and "no waste in the aluminum industry". With technology as the support, cost reduction as the focus, standardized management as the platform, and mass participation as the source, it has continued to promote cost reduction. This increases efficiency. Through continuous improvement in recent years, the branch's alumina output has increased significantly at an average rate of nearly 200,000 tons per year, from 200,000 tons in 1998 to 1.73 million tons in 2006, and the energy consumption per ton of alumina is equivalent to standard coal. However, it decreased from 2095 kilograms in 1998 to 988.95 kilograms in 2006, a decrease of 52.79%. The electricity consumption decreased from 624 degrees to 359 degrees, a decrease of 42.46%; the unit consumption of aluminum ore decreased from 2.05 tons in 1998 to 2006. 2 tons, a decrease of 2.44%; steam consumption decreased from 5.02 tons to 2.66 tons, a decrease of 47.01%.
In the past nine years, Zhongzhou Branch has produced a total of 7.51 million tons of alumina and paid profits and taxes of 8.559 billion yuan. The company has ranked first in profits and taxes in Jiaozuo City for nine consecutive years, and has been rated as "Henan Province Taxpaying Integrity Enterprise" for many consecutive years. The company's sales revenue increased from 1.027 billion yuan to 5.803 billion yuan, and the taxes paid increased from 222 million yuan to 1.562 billion yuan. It ranked 10th in the comprehensive strength ranking of industrial enterprises in Henan Province in 2005. In 2006, the Zhongzhou branch was selected as Made in China Fortune 500, ranking 394th. In 2005, Zhongzhou Branch, as the only representative of the alumina industry, was included in the list of the first batch of national circular economy pilot enterprises.
1. Implement scientific and technological innovation to provide support for energy conservation and consumption reduction
Zhongzhou Branch has always adhered to the path of combining industry, academia and research with independent innovation, focusing on resource utilization, environmental protection, Difficulties in reducing costs and increasing efficiency, such as improvement of process equipment, are the focus of scientific and technological research. In recent years, more than 200 scientific and technological achievements have been obtained, more than 20 of which are domestic and foreign firsts. 32 scientific and technological achievements have passed provincial and ministerial level appraisals, and 13 have won provincial and ministerial second-class awards; more than 50 patents have been applied for, of which 40 have been accepted by the State Intellectual Property Office and 26 have been authorized. The national high-tech industrialization demonstration project undertaken by our company, the "300,000 tons/year mineral processing Bayer process for the production of alumina new technology industrialization demonstration project" and the successful development and industrial application of the enhanced sintering alumina production process have attracted domestic attention. It has received great attention from foreign peers. Among them, the new process of enhanced sintering was called a technological revolution in my country's alumina production theory by well-known domestic experts, and won the 8th China Patent Gold Award; the industrial implementation of the Bayer process for mineral processing created a new technology in the world. It is the first of its kind to apply mineral processing technology to alumina production, and has found a technically reliable, economically reasonable new process route for the production of alumina from low- and medium-grade diaspore-type bauxite in my country; the post-adding ore thickening and dissolution project has pioneered the oxidation It is the first time in the aluminum industry to use diaspore and boehmite simultaneously in one production line. These three technologies have now become the core technologies of Chinalco's alumina production, and are recognized by domestic authorities as major key technologies for the future development of my country's alumina to change the resource situation, improve core competitiveness and ensure the sustainable development of my country's alumina.
(1) Improving the traditional process
The sintering method to produce alumina is the oldest process for producing alumina. It has the disadvantages of high energy consumption, long process and high cost. In order to improve the process, Zhongzhou Branch cooperated with Central South University to use advanced and applicable technologies to transform and upgrade traditional industries, and achieved a "new process for the production of alumina by enhanced sintering", and has successively implemented industrialization and reconstruction and expansion projects. Compared with traditional sintering methods, The annual output is increased by 300,000 tons. The energy consumption of the sintering alumina process has dropped from 1821 kilograms of standard coal in 1999 to the current 1061 kilograms. The energy consumption has been reduced by 41.7%. Energy consumption alone can save 690,000 tons of standard coal per year. Annual economic benefits exceed 100 million yuan. Zhongzhou Branch also focused on the digestion and absorption of "enhanced sintering production technology" and through full-process technical research, increased the clinker kiln operation rate from less than 90% to more than 95%, and the kiln hourly production capacity from the original 58 tons increased to 63 tons, and the kiln age increased from less than 120 days to an average of more than 200 days. As a result, the annual output of 6 clinker kilns was about 900,000 tons of alumina, and the system production capacity increased by more than 50%.
At the same time, Zhongzhou Branch has invested more than 20 million yuan to transform environmental protection projects such as electric dust collection in clinker kilns, thermoelectric boiler dust collectors, and zero discharge of industrial wastewater throughout the plant. In particular, it has used advanced foreign technology to make electric dust collection in clinker kilns The amount of external dust discharged has been reduced by more than 40%, which is much lower than the emission standards stipulated by the state. The annual recovery of alkali and water is 725 tons and 2 million tons, and the total emission of pollutants per 10,000 yuan of output value has been reduced by more than 200%.
(2) Actively develop new processes
The branch carried out research around the national "Ninth Five-Year Plan" key scientific and technological research topic - "New process for producing alumina by the Bayer process of mineral processing", and carried out research on The process has been continuously improved, and many scientific and technological achievements have been achieved, such as "selective grinding", "double-flow dissolution", "research, development and industrial application of key technologies and equipment for mineral processing-Bayer process new process". Among them, “Ore Processing—Research, Development and Industrial Application of Key Technology Equipment of New Bayer Process” won the first prize for scientific and technological progress, the only one awarded at the Second Science and Technology Conference of China Aluminum Corporation. After this process was put into production in 2004, the ore-supply aluminum-silicon ratio of the Bayer beneficiation system dropped from the traditional more than 10 to about 5.7, opening up an effective way for the full utilization of my country's low-grade diaspore-type bauxite resources. way. According to estimates, through the application of the new Bayer process of beneficiation, the economic service life of the current bauxite resources in our province can be increased by more than three times. Compared with the hybrid method mainly used in China, the new Bayer process of mineral processing can save 15% to 20% in construction investment, reduce production costs by 10%, and reduce production energy consumption by 50%. At the same time, the Zhongzhou Branch has applied the Bayer process post-dissolution ore-enhancing technology and added foreign boehmite to the last dissolution vessel. The production capacity will be increased by 60,000 tons with a small increase in investment. Thermal energy can be fully utilized, which not only increases production capacity, but also facilitates the production of sandy alumina, saving 50% of unit investment in alumina compared with conventional investment. The project successfully put materials into operation on September 30.
(3) Cascade utilization of resources
In order to make full use of the resource advantages of sintering method to produce alumina, and realize the industrial chain of cascade utilization of resources. Zhongzhou Branch continues to increase its efforts in the development of chemical alumina, and has independently developed more than 10 high-tech products in three series: dry white aluminum hydroxide, ultrafine aluminum hydroxide and high white aluminum hydroxide. Among them, SH-M75 dry white aluminum hydroxide was recognized as a national-level new product, and ultra-fine and high-white aluminum hydroxide was recognized as a high-tech product in Henan Province. The product not only has the advantage of high added value, but also has the advantage of environmental protection. Its raw material comes from the solution in the middle of alumina production, and the waste liquid from the production of chemical alumina can be returned to alumina production, so the production process does not produce any pollution and can reduce the cost of alumina production. This is a separate chemical alumina plant. Incomparable. The development of the chemical alumina has turned the branch's economic activities into a feedback process of "resources-products-renewable resources". Materials and energy are rationally and permanently utilized in the economic cycle, thus making "reduction ", reuse, recycle" has become a reality. At present, the production scale of chemical alumina has reached an annual output of 130,000 tons. The whiteness of the products is generally above 94%, and the annual export earnings exceed 9 million US dollars.
(4) Recycling of energy
In terms of promoting alternative technologies, the branch continues to improve advanced technologies such as the enhanced sintering method, the Bayer method of mineral processing, the high-temperature dual-flow dissolution, and the substitution of coke with lump coal. and technology; in terms of promoting weight reduction technology: Continuously improve the technical conditions of new equipment such as alumina indirect heating desiliconization, mother liquor tube falling film evaporation, and high-efficiency CO2 compressors, making the mother liquor tube falling film evaporation technology applied to the sintering method for the first time system, significantly reducing steam consumption.
(5) Implementing cleaner production
The branch has invested more than 40 million yuan in the transformation of environmental protection projects such as electric dust collection in clinker kilns, thermoelectric boiler dust collectors, and zero discharge of industrial wastewater. And actively promote reuse technology. At present, multiple uses of water (zero discharge of industrial wastewater, red mud return water, ash return water and reuse of evaporation return water) have been achieved; cascade utilization of heat (high-pressure steam power generation, medium-pressure steam dissolution, low-pressure steam evaporation , exhaust steam is used for heating); not only achieves zero discharge of industrial wastewater, but also recovers more than 700 tons of alkali and 2 million tons of water every year.
At the same time, the branch actively carries out scientific and technological research around the comprehensive utilization of mineral processing tailings, ash and red mud. The feasibility study report of the ash dry storage plan has been reviewed and will be implemented before the end of the year. The tailings and red mud comprehensive utilization plan has been developed in cooperation with relevant universities.
2. Implement standard quantitative management to provide a platform for energy conservation and consumption reduction
Zhongzhou Branch has introduced a standard quantitative management model, focusing on three aspects: quantitative management, standardized management and continuous improvement management. In this link, we focused on improving the internal operating mechanism to ensure the implementation of energy conservation and consumption reduction work from an institutional perspective.
(1) Implement benchmarking, conduct all-round benchmarking, and quickly improve corporate management level
The branch aims at a high starting point to benchmark against outstanding companies in the international industry such as American Aluminum and Canadian Aluminum. We have established a first-class indicator system including benchmarking against design, benchmarking against the highest historical level, and benchmarking against the advanced level of the international industry, and included it in the performance appraisal plan for assessment. Through systematic planning and phased advancement, 40% of the indicators in the entire indicator system hit record highs every year. Last year, 35 of the company's 45 internal indicator innovation systems hit record highs, and major economic indicators hit record highs. In terms of quality indicators, the company requires metallurgical-grade alumina to be benchmarked against international sand alumina technology, and chemical alumina to be benchmarked against Japan's Sumitomo products and American Albemarle products, so that product quality has been greatly improved in a short period of time. Amplitude increase. In terms of energy saving and consumption reduction indicators, the energy consumption per ton of alumina process has dropped from 1344.67 kilograms of standard coal in 2001 to the current 882.52 kilograms, a decrease of 34.37%. Major technical indicators such as steam consumption and alkali consumption have reached advanced levels respectively, and 5 indicators were selected into the "New Records of Chinese Enterprises" by the China Enterprise Confederation. Alumina indirect heating desiliconization, tubular falling film evaporation, high-efficiency CO2 compressor and other reduction technologies and the reuse of water, steam and other energy have also made great progress. The wastewater recycling alone saves new water every day. 10,000 cubic meters.
(2) Establish a quantitative management system such as budget value and standard cost
In order to build a standard quantitative management platform, the branch company has continuously improved the construction of the measurement network and established a system centered on optimizing production management. The budget value management system and the standard cost management system centered on optimizing financial management. At present, the construction of the measurement network of Zhongzhou Branch has been basically completed. The team can see the consumption cost on the shift, and the workshop can see the consumption cost on the day. The relevant assessment system is also being gradually improved. The establishment of these two systems has created conditions for the successful implementation of the company's ERP project.
(3) Improve responsibilities and establish a responsibility system for creating resource-saving enterprises
Zhongzhou Branch conducts a detailed breakdown of the goals, content, and measures for scientific and technological energy conservation and management energy conservation every year, and formulates The continuous improvement plan, in the form of a countermeasure table, introduces implementation plans for technical research, technological transformation, management innovation and other project topics, and determines the project leader, target measures, completion deadlines, performance evaluation, etc. In order to implement various goals and measures in place, the company has established a supervision mechanism, which is supervised by the general manager's office and reports on the implementation of various tasks every month. In order to encourage each unit to implement the implementation plan for creating a resource-saving enterprise, Zhongzhou Branch has also established a continuous improvement operating mechanism, set up a continuous improvement management innovation performance award, inspected the implementation of energy saving and consumption reduction every month, and reviewed the project projects. Achievements are rewarded in 6 levels.
3. Encourage the participation of all employees to provide a rich source of energy saving and consumption reduction
Zhongzhou Branch always regards employees as the most valuable wealth, adheres to the policy of relying on employees wholeheartedly to run the enterprise, and builds As a platform for talent development, we encourage employees to innovate, actively carry out mass innovation activities such as advanced operating methods, labor competitions, and independent management, and mobilize all employees to save energy and reduce consumption.
(1) Establish a mass innovative operation model mainly carrying out the "Five Smalls" and "Ten Ones" activities
The "Five Smalls", that is, small designs and small tips , small inventions, small creations, small innovations; "Ten Ones", that is: save a drop of water, a drop of oil, a piece of paper, a penny, a kilowatt hour of electricity, one or two coals, one screw, one or two alkali, one or two Ore, one kilogram of gasoline. Focusing on this subject, mass innovation activities such as "Strive to become an expert in energy saving and consumption reduction" and "I will contribute to reduce costs" have been carried out to reflect the sense of responsibility and mission of the employees from multiple angles, from key research to small reforms. Zhongzhou Branch promptly discovers and rewards employees' rational suggestions and advanced operating methods, and implements an advanced operating method evaluation system named after employees. Since 2002, more than 30 advanced operating methods named after employees have emerged, including the "Spring Water Operation Method" and the "Guoqiang Fire Watching Method", which have produced good economic benefits.
Last year, *** collected 2,548 rationalization suggestions from employees, adopted 1,643, and implemented 1,025 waste material utilization, resulting in a total of 3.01 million yuan and a savings of 5.77 million yuan.
(2) Carry out various forms of labor competition activities to encourage employees to save energy and reduce consumption in an all-round way
Carry out labor competitions such as Youth Indicator Challenge Competition, Indicator King Team Team, and Create Maintenance Brand activities and establish an incentive mechanism. By carrying out brand team competitions, the team has mastered more key technical know-how, cultivated a group of brand teams with excellent technology and excellent work style, and carried out all-round energy conservation and consumption reduction, so that the activities of creating resource-saving enterprises can truly be implemented at the grassroots level. During the construction of the mineral processing Bayer process project, Zhongzhou Branch launched a special competition for key projects. The first production line was completed and put into operation in only 14 months, and the second production line was completed and put into operation in only 264 days, creating a world-leading oxidation A miracle in the history of aluminum construction, it is known as "Zhongzhou Speed". In recent years, Zhongzhou Branch has allocated 1 million yuan every year as special labor competition expenses, carried out 392 various competition activities, and achieved remarkable results.
(3) Carry out research activities on autonomous management topics with teams as the main body
Focusing on cost reduction and efficiency improvement, standard quantitative management tools are used to maximize the autonomy of grassroots employees. and creativity. In the pilot branch factory, each team has determined autonomous management research topics, and the workshops and branches publish results from time to time. Through team and group independent management research activities, the team's independent management level has been raised to a new level, and many " "Learning Team", "Resource-Saving Team", "Innovative Team", etc., and have won more than a dozen national and provincial innovation demonstration positions.
Four. Grasp the positioning of the production cost center and continuously improve the intrinsic quality of production operations
The branch firmly grasps the positioning of the production cost center and establishes a production linkage based on cost budget control. The command system and management system have achieved "simplification, efficiency, unification, and consistency of rights and responsibilities", creatively carried out various management tasks, continuously expanded the connotation of cost reduction, and successfully completed the production and operation tasks of each year.
(1) Optimize production organization and ensure system balance and stability
In terms of production organization, the branch fully implements the work policy of "safety, efficiency, balance and stability" and adheres to the principle of boiler Taking steam balance as the center, we strengthen dispatching and command, optimize production organization, and ensure balanced and stable operation of the production system.
In the sintering system, the economic and stable operation of the production system has been achieved through research on the economic operation modes of carbon separation, desiliconization, red mud drainage and water return, steam supply, and air supply. In the Bayer process system, in view of the problems existing in the optimization of bauxite flotation process, the filtration and settlement of fine tailings and the recycling of mineral processing water, through system research, technical secondary development and optimization of economic and technical indicators, The stable and high-yield operation of the Bayer process production system is maintained. The branch adheres to the implementation of all-round elimination of waste by all employees, and has carried out mass economic and technological innovation activities such as "Ten Cost Reduction Achievements, Hundreds of Cost Reduction Experts, Five Small and Ten Ones", and the majority of employees have firmly established the concept of eliminating waste without limits. , achieved good results. In 2006, compared with the cost target issued by the headquarters, the branch's annual comprehensive alumina cash cost decreased by 5.45 yuan/ton. Through the rapid increase in output, the annual physical alumina output per capita has increased from 11 tons at the beginning of the plant to the current 349 tons, achieving rapid growth and setting a record high in the country.
(2) Consolidate the foundation of equipment management and achieve safe and efficient operation
In terms of equipment management, the branch continuously consolidates the foundation of management, improves the management level, and realizes the "safety and efficiency" of the equipment system. "Economic, efficient and stable" operation provides a reliable basic guarantee for sustained, stable and high-yield production. In March 2005, Zhongzhou Branch trial-operated the "Equipment Management Model with the Spot Inspection System as the Core". Currently, the operation is standardized, and the inspection, maintenance, and operation are coordinated and orderly. The spot inspection work has achieved remarkable results. In 2003, Zhongzhou Branch was rated as a national advanced unit in equipment management. In 2006, the branch's clinker kiln and high-pressure dissolution operation rates reached 96.9% and 96.7% respectively, and the boiler operation rate reached 98%. Production capacity increased simultaneously and equipment conditions continued to improve.
(3) Establish the concept of continuous improvement and innovate the enterprise management model
Since 2002, Zhongzhou Branch has based on the summary of past practical management experience and in accordance with the requirements of modern enterprise management , put forward the new concept of "continuous improvement", adhered to pragmatic innovation, implemented "systematic operations and phased advancement", and promoted various professional management. In accordance with the requirements of the listed company's management model of "centralized management and authorized operation" and the corporate governance structure, reshape the business process, establish a new target assessment and incentive mechanism, and consciously obey the policies of Chinalco in finance, material distribution, sales, investment and technology research and development Vertically centralized management of five functions. Zhongzhou Branch was the first to establish a comprehensive budget management system with single set accounting as the core content among all member units of Chinalco, forming a unified accounting system and centralized fund management model; it was the first to establish a material distribution center and cancel the second The level warehouse realizes the separation of procurement, quality control and acceptance and the centralized allocation of inventory, improves logistics efficiency and promotes the centralized management of China Aluminum Logistics. The exploratory experience gained from the single set accounting and centralized material distribution model is still being fully promoted by Chinalco; sales management strictly implements the relevant policies of Chinalco and establishes long-term and stable cooperative partnerships with customers; investment management is strictly implemented The company's headquarters investment plan strengthens the "four major controls" of project construction. The completion of technical transformation and infrastructure investment has set a new record since the establishment of the factory for two consecutive years. One project won the National Excellent Silver Award.
Promote three system reforms and accelerate informatization construction. The branch used the reform of the distribution system as a breakthrough to widen the gap in job bonus distribution, effectively implemented three system reforms, and established a competitive recruitment system for management personnel. The three effective incentive mechanisms form a new mechanism in which management personnel rely on performance and income distribution depends on contribution.
In terms of information construction, the ERP project of Zhongzhou Branch was successfully launched on June 1, 2006. It is currently running stably and has played a positive role in standardizing the branch's business processes. The branch has established an information work leading group to bring ERP, GCC, 404 and other tasks under unified leadership, strengthen organization and coordination, and actively promote the progress of various tasks. With the care and support of Chinalco, Zhongzhou Branch is carrying out standard quantitative management pilot work. At present, it has basically realized real-time collection and network transmission of power and material quantities, and has initially realized the quantitative decomposition of production costs.
Looking back on the "Tenth Five-Year Plan", Zhongzhou Branch relied on the correct leadership of the company's party group and the strong support of governments at all levels, and with the joint efforts of all employees, it achieved the highest level of China Aluminum Corporation from the time of listing. The weak link is the dramatic change in the best enterprise in the three comprehensive indicator assessment systems: physical labor productivity of all employees, profit and tax per capita contribution, and return on assets. Zhongzhou Branch has successively won the honorary titles of Henan Province’s “May 1st Labor Certificate”, Henan Province’s first batch of “Green Enterprises”, “Cleaner Production Demonstration Enterprises”, “Henan Province Advanced Quality Management Enterprises” and “Henan Province’s Largest Integrity Taxpayers”.
Looking forward to the "11th Five-Year Plan", Zhongzhou Branch will focus on the development goals of the company headquarters to "create a world-class enterprise and build a century-old Chinalco store", adhere to the people-oriented approach, establish and implement the scientific development concept, and accelerate the development of the enterprise. Development pace, strive to create a resource-saving enterprise, in order to build Zhongzhou Branch into a high-tech integration, develop circular economy, comprehensive utilization of resources, significantly reduce energy consumption, internal harmony within the enterprise, full of vitality in the team, fixed assets and sales revenue both exceeded 5 billion We will work hard to build a large-scale aluminum industrial base in Yuan!