Style Record| Guided by the concept of "five modernizations" and digital transformation as the core

Zhengzhou Ruitai Refractory Technology Co., Ltd.(hereinafter referred to as Zhengzhou Ruitai) is affiliated to Ruitai Technology Co., Ltd., a subsidiary of China Building Materials Group. It was founded in 1984 and is located in Xinmi City, Henan Province, known as the "Hometown of Refractories." Zhengzhou Ruitai has a registered capital of 105 million yuan, covers an area of 260 acres, and has 220 employees. It is a manufacturing company that provides various refractory materials services for high-temperature kilns in the industries of building materials, nonferrous metals, new energy, carbon power, etc., and is also a technology-based enterprise integrating research and development, production, sales, international trade and technical services.

Zhengzhou Ruitai mainly produces new high-temperature refractory materials for industrial kilns in nonferrous metals, cement and other industries, with an annual production capacity of 110,000 tons. It also provides supporting refractory materials and personalized services such as construction and installation for thermal kilns. Zhengzhou Ruitai's comprehensive strength in production capacity, technological innovation, product quality, service level and other comprehensive strengths are leading the industry.

Zhengzhou Ruitai takes the strategic positioning of "building a domestic first-class and internationally renowned supplier of high-temperature new materials" to promote high-end and green products. Integrate green development into the entire process of Zhengzhou Ruitai production, practice green manufacturing from aspects such as system construction, product research and development, and factory transformation, strive to achieve a virtuous cycle of the ecosystem and economic system, and achieve the organic unity of economic, ecological, and social benefits. Relying on the quality, ecology, environment, energy, occupational health and safety systems, we will build a strict management system, improve the management structure, and benchmark international and domestic standards in all aspects of production management. In August 2017, Zhengzhou Ruitai became one of the first batch of national-level green factory demonstration units in the refractory industry of the Ministry of Industry and Information Technology. It is the first green factory in the national refractory industry. At the same time, it has also won the honorary titles of Green Leading Enterprise in Henan Province, A-level Enterprise in Environmental Protection Performance, Henan Province Energy Conservation and Environmental Protection Demonstration Enterprise, Henan Province Advanced Enterprise in Green Development, Henan Province Energy and Carbon Management Demonstration Enterprise, and Henan Province Carbon Asset Management Demonstration Enterprise.

In recent years, Zhengzhou Ruitai has continued to exert its green actions around the "five modernizations" concepts of "ultra-low organized emissions, systematization of unorganized emissions, clean transportation methods, forest environment in the factory area, and green and energy-saving products". Through the simultaneous implementation of multiple measures of "management, control, treatment, reform and use", ultra-low emissions of air pollutants in the entire process have been achieved, and the company has achieved remarkable results in its green and low-carbon development.

Ultra-low organized emissions

Since 2018, Zhengzhou Ruitai has invested more than 50 million yuan in environmental protection. Based on the combustion process characteristics of tunnel kiln, it has finally determined the flue gas treatment process of "dry desulfurization, bag dust removal, and SCR denitrification". The desulfurization, denitrification and dust removal equipment is designed with an air volume of 100,000 to meet the treatment needs of four tunnel kilns. The flue gas is collected through the equipment for centralized treatment, enters the desulfurization tower, and reacts with the baking soda sprayed out from the tower, thereby eliminating sulfur dioxide in the flue gas. Then the flue gas enters the dust removal equipment. The flue gas after bag dust removal enters the denitrification tower and is catalyzed by the catalyst in the denitrification tower to achieve the purpose of denitrification, and finally reaches the ultra-low emission standard of flue gas, that is, nitrogen oxides ≤50mg/m³, sulfur dioxide ≤35mg/m3, particulate matter ≤10mg/m³。

At the same time, Zhengzhou Ruitai invested more than 600,000 yuan to purchase imported ultra-low emission monitoring equipment to monitor emission data in real time to ensure stable compliance. The treatment process does not produce new hazardous waste, no secondary pollution, and no white feather phenomenon occurs in the chimney; all equipment is automatically controlled, and the amount of injected material is automatically adjusted at any time according to the smoke content, saving labor costs and ensuring ultra-low and stable emissions.

Systematization of unorganized emissions

Zhengzhou Ruitai took the initiative to tackle the problem and formulated unorganized management and control measures for comprehensive monitoring and systematic management in view of the characteristics of many, wide-ranging and difficult to control. A closed raw material warehouse of more than 6000 square meters has been built, and all raw materials have been stored in storage. 69 pulse cartridge dust collectors, 5 vehicle-mounted mobile dust collectors, 1 set of high-pressure spraying equipment, and two mobile high-pressure dust and fog control cannons were installed. At the same time, unorganized PM was built_2.5、PM₁₀Environmental monitoring points in the particulate matter factory area, as well as dead-corner monitoring in production workshops, and chain control procedures for environmentally friendly dust removal equipment, use machine pipes instead of human pipes to monitor all emission data online, realizing automated operation of the environmental protection system and normalized management and control of unorganized emissions. Green development is inseparable from "smart" support, which is not only reflected in the main production links, but also reflected in the greening and intelligence of the entire life cycle.

Clean transportation methods

During the production of refractory materials, a large amount of dust will be generated during the transfer of raw materials and ingredients, posing a risk of endangering human health. Through the "5G+ independent ingredients" solution, Zhengzhou Ruitai uses 5G's highly reliable network and positioning capabilities to achieve millimeter-level positioning and docking for ingredient transfer. The ingredients do not leak, achieve dust-free and unmanned workshops, and increase the equipment operating rate by 12.5%. It provides strong support for the company's high-quality production.

Zhengzhou Ruitai builds an access control system and video surveillance system to monitor and record the entry and exit of transportation vehicles into and out of the factory. It uses license plate recognition technology to automatically record vehicle information entering and leaving the factory, including license plate numbers, vehicle types, etc.; combined with vehicle emission stage information (such as the National Fifth and National Sixth Emission Standards), make preliminary judgments on vehicle emissions and intercept vehicles that do not meet the requirements; install high-definition cameras to conduct full video surveillance of vehicles entering and leaving the factory to ensure that they are documented; Conduct statistical analysis of the collected data to provide data support for environmental management and safety decisions. Vehicles that do not meet the requirements are prohibited from entering and leaving the factory area. The proportion of bulk materials and products entering and leaving the factory area is transported in clean methods reaches 100%.

Forest environment in the factory area

A good factory environment and high greening rate not only allow the factory to maintain a good ecology and improve air quality, but also reduce noise spread, which is an important symbol of a green factory.

"Greening and never hardening" is the ecological construction concept that Zhengzhou Ruitai has always adhered to. In order to beautify the ecology of the factory, achieve "forest" of the factory environment, and "fully green" of exposed land, Zhengzhou Ruitai invested 3.5 million yuan to plant more than 20 varieties of arbor trees such as camphor, osmanthus, and ginkgo, as well as various shrubs, hedges, and lawns., achieving "flowers in three seasons and evergreen in all seasons", with a greening rate of 30%. Now entering the Zhengzhou Ruitai factory area, you will find trees, flowers, fragrance, insects and birds singing, as if you are in a garden.

Green and energy-saving products

To build a domestic first-class and internationally renowned supplier of high-temperature new materials, Zhengzhou Ruitai understands the importance of high-end, green and energy-saving products. This requires integrating green development into the entire process of production, starting from system construction, product research and development, factory transformation, etc., and practicing green manufacturing throughout the process, striving to achieve a virtuous cycle of the ecosystem and the economic system, and achieving economic, ecological, and social benefits. Organic unity of benefits.

According to the new requirements of relevant management departments for synergy in pollution reduction and carbon reduction, energy conservation and carbon reduction are top priority for production enterprises. The high-temperature new materials industry must not only accelerate the promotion of ultra-low emission transformation, but also transform and leapfrog in development, and fundamentally move towards the path of high-quality development.

After unremitting efforts, Zhengzhou Ruitai has obtained two major inventions: magnesium-iron-aluminum (chromium-free) spinel bricks and low-thermal-conductivity multilayer composite mullite bricks.

As an environmentally friendly alkaline refractory for cement kilns, magnesium-iron-aluminum (chromium-free) spinel bricks replace traditional magnesium-chromium bricks, completely eliminating the harm of hexavalent chromium ions to the environment and human body, and obtaining 4 national invention patents.

The self-developed low-thermal conductivity multilayer composite mullite brick is an environmentally friendly "energy-saving product". This product is used in large cement rotary kilns, and the kiln body temperature can be reduced by 100 ° C. Each ton of cement clinker produced can reduce the amount of standard coal by 1.5kg. Taking a cement rotary kiln with a daily output of 5000 tons as an example, after using this product, 7 tons of standard coal can be saved every day, and a cement kiln can save about 2300 tons-3300 tons of standard coal a year; carbon dioxide emissions are reduced by 5880 tons, sulfur dioxide emissions are reduced by 184 tons, nitrogen oxide emissions are reduced by 253 tons, and other dust and harmful gas emissions are reduced by 460 tons. Low thermal conductivity composite bricks not only reduce production costs for cement companies, but also contribute to air pollution control.

While adhering to the concept of "five modernizations", Zhengzhou Ruitai focuses on intelligence and digitalization to help green and low-carbon development. In recent years, under the strategic guidance of China National Building Materials Institute and Ruitai Technology, Zhengzhou Ruitai has focused on the digital strategic plan of the National Building Materials Institute, with "industrial digital transformation" as the core, and fully implemented the "intelligent transformation and digital transformation" work of production-oriented enterprises. In the transformation work, we adhere to a result-oriented approach, focus on industrial pain points, and combine the General Hospital's concept of "digital value improvement" to further promote industrial "rejuvenation" and realize the reprocessing and upgrading of accumulated data. In accordance with the strategic goal of building a "Digital General Academy", we will vigorously develop the digital economy and promote the transformation and upgrading of traditional industries.

The 5G smart factory built by Zhengzhou Ruitai has built a "1+1+N" smart factory architecture, deployed a 5G private network, and developed an industrial Internet platform and "N" application scenarios. Through the construction of system software and hardware, the system can realize information integration with ERP and automated production lines, and realize the collection, management and feedback of man-machine and material method information in the production and manufacturing process. Based on the 5G public network architecture, 5G+MEC is used to open up data connections for all business processes through a dedicated channel for 5G network. Through the combination of 5G+ data collection and industrial Internet data, planning, production, quality, equipment, barcode traceability, inventory, intelligent multi-scenario management and control of the entire process such as energy, safety and environmental protection are realized.

At present, Zhengzhou Ruitai Intelligent Factory Management and Control System realizes all digital management and control in the refractory manufacturing process, including production planning, job dispatch, inventory and other management, as well as equipment networking, automatic real-time data collection, industrial big data analysis and on-site Kanban Display, etc. In the production process, the process from crushing, batching, forming, firing to testing and packaging is fully automated, digital, networked and intelligent.

Through industrial Internet integration and innovation, Zhengzhou Ruitai has successively won the titles of national-level intelligent manufacturing demonstration factories, national-level intelligent manufacturing pilot demonstration excellent scenarios, national-level specialized and new small giant enterprises, national-level new generation information technology and manufacturing integrated development Demonstration enterprises, national-level industrial Internet pilot demonstration enterprises, national-level intellectual property advantage enterprises, Henan Province intelligent factories, Henan Province's first batch of "5G+ smart factories", The first batch of 5G application scenario demonstration enterprises in Henan Province, the new generation information technology integrated application new model demonstration enterprises in Henan Province, and the quality benchmark enterprise in Henan Province.

Refractory materials are the foundation of traditional manufacturing. Faced with high-quality development requirements and the realization of the "double carbon" goal, the traditional refractory materials industry is facing unprecedented challenges. In terms of product quality, we must continue to pursue longevity and efficiency, energy conservation and consumption reduction, and green environmental protection; in terms of production, we must meet safety, environmental protection, and occupational health regulatory requirements, and constantly innovate green, intelligent, and efficient production models. In the next step, Zhengzhou Ruitai will continue to improve its green and intelligent levels in production and operations and continuously improve operational efficiency. On this basis, we are committed to promoting green and intelligent innovative production models in the industry and contributing to the green and intelligent high-quality development of the national refractory industry.

Published in the sixth page of "China Environment News" on September 24, 2024