Inspectors make China National Color Daye Smelter realize green transformation
Production area of converter main building
ausmelt furnace
intelligent operation Center
Center garden
Panorama of the smelter
An old smelter with a history of 67 years has been reborn under the influence of the central ecological and environmental protection inspector. This is the story that the smelter of Daye Nonferrous Metals Co., Ltd.(hereinafter referred to as Zhongse Daye Smelter) is experiencing.
High-quality development is inseparable from high-level protection. As a leading state-owned enterprise in the non-ferrous industry, China National Color Daye Smelter, under the leadership of China Nonferrous Metals Mining Group Co., Ltd.(hereinafter referred to as China Nonferrous Metals Group), seeks development and opens a new situation to build an industry benchmark enterprise and takes green development as its own responsibility. Today's Zhongse Daye Smelter has fully implemented intelligent transformation of environmental protection and industrial upgrading, introduced advanced technology and equipment, improved quality and efficiency, and built a modern and intelligent green copper smelter, creating a green and high-quality development path.
shoulder the responsibility of green development and calculate political, economic and environmental accounts
Walking into the Zhongse Daye Smelter, the green in front of you is not only the green of the tall trees in the factory, but also the "green" of craftsmanship and development. The modern factory area is clean and tidy, and the Ausmelt furnace stands at the foot of Changle Mountain. It is not only a landmark building of the factory, but also a powerful witness to the green background of high-quality development.
Taking the rectification of the central ecological and environmental protection inspection issue as an opportunity, China National Corporation Daye Smelter clarified key aspects of development and strived to set an example in terms of high-quality development, synergy and efficiency reduction, and comprehensive fulfillment of its main responsibilities for ecological and environmental protection.
In the smart central control room of the smelter, a large electronic screen displays air quality monitoring data in real time. The pollutant control and emission situation are truly and accurately presented to the staff, reflecting the new look of science and technology and environmental protection.
In 2021, the second round of the fourth batch of central ecological and environmental protection inspectors reported the serious emission of flue gas from the China National Automobile Daye Smelter and excessive heavy metals in the discharged wastewater. Regarding the problems pointed out by the inspectors, China National Automobile Daye Smelter fully claimed and accepted all the orders, with firm thoughts and decisive actions. According to the "cases" and "prescriptions" prescribed by the inspection team, a "green revolution" to improve quality and efficiency was launched.
"At that time, we initially estimated that to completely solve environmental protection problems, we might invest nearly one billion yuan, which is a lot of pressure for an old smelter." said Hu Xiaojun, deputy chief accountant and chief of the finance section of the smelter.
Pressure and difficulties have further prompted the rectification work to make a fuss about industrial upgrading, energy conservation and emission reduction, and the elimination of backward production capacity. During the rectification work, Zhongse Daye Smelter resolutely calculated the political, economic and environmental accounts, and integrated the concept of green development into the company's strategic layout and production and operation.
In the second half of 2021, Xi Zhengping, Secretary of the Party Committee and Chairman of China Nonferrous Metals Group, twice led a team of experts to go deep into the scene to find problems and collect a large amount of first-hand data and materials. The expert team conducted a detailed analysis and diagnosis of the on-site situation, formulated a series of targeted solutions, and finally finalized the implementation plan of the project: dismantling a converter and shutting down a sulfuric acid system, but keeping the output unchanged.
In Xi Zhengping's view,"the rectification of ecological and environmental protection inspections is a 'touchstone' to test whether leading cadres are firm in their attitude, whether their stance is firm, whether they are loyal to the party, and whether their abilities are strong. In the face of rectification tasks, no luck mentality or mentality must be allowed. We must resolutely be 'strict,''meticulous' and 'practice'." We will truly implement the reform, achieve results, achieve the organic unity of social benefits, economic benefits and environmental benefits, and give the old factory new vitality.
The main leaders of the group headquarters and China National Corporation Daye continue to be guided by Xi Jinping Thought on Ecological Civilization, change concepts, improve their stance, unswervingly follow the path of ecological priority and green development, and resolutely shoulder the political responsibility of ecological civilization construction and ecological environmental protection. Give full play to the demonstration and leading role of central enterprises.
Implement "double-high test exploration measures" to achieve the "acceleration" of green development
"Dismantling a converter, shutting down a sulfuric acid system, and the output remains unchanged." This is a huge challenge for an old smelter. When green development becomes the theme of the times and energy conservation and carbon reduction become the mainstream of the industry, opportunities and challenges coexist. Zhongse Daye Smelter faced the difficulties and launched the "Double High Test Exploration Measures" project. This is an industrial revolution and an ideological innovation. China National Color Daye Smelter has launched multiple explorations in technological innovation, environmental protection, and improvement of quality and efficiency.
The smelter tried to cancel the granulating process, but after the granulating process was stopped, the amount of soot increased and the copper content in soot increased. When trying to reduce the amount of converter blowing flue gas and implement high-grade operations, it was found that the melting point of the matte increased, which led to an increase in the viscosity of the matte. In order to solve this problem, the smelter changed the material of the matte chute from a ceramic chute to a copper water jacket chute, which solved the problem that the matte bond was difficult to clean. However, it also found that the copper water jacket chute posed a greater safety risk. If burned, the matte will easily explode when it meets water... Solving one problem will soon usher in another new problem.
"We have been confused many times. Many times we felt that we couldn't continue halfway through the experiment, but there was no way out. We had to move forward." said Wan Liming, deputy general manager of Zhongse Daye, secretary of the party committee and director of the smelter. It is this situation of no retreat that builds the determination to be reborn without hesitation.
In order to prevent building cars behind closed doors, while "building internal skills" and "strengthening physical fitness" and improving their own technical level, old smelters insist on "going global" and learning advanced technologies. They went to Yunnan Copper Southwest Copper and Yimen Copper Company for inspection and study, and went to Tongling Nonferrous Metals Jinguan Copper Company and Jinlong Copper Company for benchmarking research;"Please come in" and invited top scientific research teams such as Enfei to enter the factory for on-site inspection and discussion. Find out the root cause of the problem and propose solutions by "going out, please come in".
More than 1000 technicians and operators in the factory have achieved a series of results after more than 700 days and nights of repeated exploration and testing for two years. The copper content in ash has dropped by more than 4%, the amount of flue gas has been effectively controlled, the copper processing capacity of a single furnace has increased significantly, and the output has been maximized. After repeated verifications, the set goal of "dismantling one converter, shutting down a sulfuric acid system, and maintaining the same output" was finally achieved.
On March 24, 2023, the fourth sulfuric acid series of the smelter, which has been in operation for 19 years, was completely suspended. One converter in the converter workshop was demolished simultaneously. The shutdown of the system and the demolition of the converter not only demonstrated the determination to environmental protection rectification, but also predicted the company's new chapter. Opening.
"Environmental protection upgrades not only solve environmental protection problems, but also create greater value through process changes and industrial upgrades." Hu Guobin, Secretary of the Party Committee and Chairman of China National Color Daye, said,"Only by solving the major environmental protection problems can we go into battle easily and achieve the 'acceleration' of green and high-quality development."
Using technological upgrades to stimulate the momentum and potential of green development, and change from a "typical pollution" to a "model of pollution control", China Color Daye is still continuing to explore.
Control dust, gas and slag, comprehensively and thoroughly upgrade and transform
Against the background of the global response to climate change, pollution reduction and carbon reduction are not only a passport for enterprises in the international competitive market in the future, but also a lifeline for enterprises 'own high-quality development.
The "Implementation Plan for Carbon Peak in the Nonferrous Metals Industry" jointly issued by the Ministry of Industry and Information Technology, the National Development and Reform Commission, and the Ministry of Ecology and Environment proposed that during the "14th Five-Year Plan" period, the structure of the nonferrous metals industry and energy use structure will be significantly optimized. Important progress has been made in the research and development and application of low-carbon processes, with the supply of recycled metals accounting for more than 24%. During the "15th Five-Year Plan" period, an industrial system with green, low-carbon and circular development in the non-ferrous metals industry was basically established.
CCSE Daye has always been based on major national principles and policies to set its direction and seek development.
In order to achieve immediate reform, the smelter invested 6.26 million yuan, which took 6 months. All problems such as flue gas leakage and unorganized emissions, imperfect rain and sewage diversion, and irregular sewage treatment measures were rectified and passed the superiors. Acceptance cancellation.
On March 21, 2023, the comprehensive environmental protection upgrade of the smelter officially kicked off. In terms of people, finances, materials and other aspects, from China Nonferrous Metals Group to China National Metals Daye, to smelters, they are all going all out to invest.
In terms of dust control, the smelter invested 39 million yuan to upgrade the system, discontinued the No. 1 and No. 2 concentrate warehouses, reduced nearly 30 transfer belts, and discontinued 4 pelletizers, which greatly reduced water and electricity energy consumption and reduced metal losses. At the same time, the dust problem in the factory has been effectively managed.
In terms of gas control, 270 million yuan has been invested to implement the transformation of pyrotechnic smelting areas, and 100 million yuan has been invested to build two new flue gas desulfurization systems to ensure that the SO2 and particulate matter content in the tail gas of the system are lower than the "Copper, Nickel, and Cobalt Industrial Pollutants Emission Standards"(GB25467-2010).
In terms of slag control, 47 million yuan was invested to upgrade the waste acid treatment process to reduce the output of hazardous waste residue.
In terms of water control, 127 million yuan has been invested to build rainwater collection ponds, transmission and treatment systems in the smelter. All types of wastewater will be reused and discharged in stages. The factory will realize "rainwater and sewage diversion, clean and sewage diversion, quality treatment, and cascade recycling."
Invest 80 million yuan to transform the sulfuric acid system, invest 40 million yuan to implement intelligent system upgrades, invest 50 million yuan to build a green factory... The investment in real money is in exchange for a comprehensive transformation of the smelter.
While implementing the upgrade and transformation, the major overhaul of the metallurgical and chemical system is underway simultaneously, and the production of the electrolysis system is still continuing. The superposition of multiple tasks has brought tremendous pressure on production, operation and management. During the upgrade and renovation, more than 1000 people need to be monitored for safety every day at the job site. It is necessary to ensure both the construction period and the construction quality of each project. It is undergoing severe tests every moment. In order to ensure construction safety, the smelter has dispatched 296 people to the site to conduct safety supervision, arranged departments and local units to implement man-to-person in sections and zones, and trained 5999 outsourced construction personnel (times), achieving "zero accidents" throughout the renovation period.
In order to ensure the quality of the construction period, the smelter has formed a critical team for maintenance and technical personnel across the plant to provide emergency support for the construction of key projects. More than 60 professional and technical personnel from the plant have formed a special work team to conduct special discussions on project drawings and construction progress. Urge equipment orders and shipments according to the progress of the project construction. Key party members launched more than 100 raids (times) around key and difficult points in the renovation, solving more than 400 on-site construction problems and safety hazards, effectively ensuring the smooth progress of the rectification work.
From ideas to concepts, from facilities to technology, China Sports Daye has ushered in a complete baptism and rebirth.
From equipment upgrades to ideological leaps, comprehensively realize green change
Chinese-style modernization is a modernization in which man and nature coexist harmoniously. We must adhere to sustainable development, adhere to the policy of giving priority to conservation, protection, and natural restoration, protect the ecological environment like protecting our eyes, and unswervingly pursue production development and prosperity., a civilized development path with good ecology and achieve sustainable development of the Chinese nation. As a central enterprise, it should contribute to the fundamental plan of realizing the sustainable development of the Chinese nation.
Implement Xi Jinping's Thought on Ecological Civilization. The Central Ecological and Environmental Protection Inspectorate is a profound ideological education for the cadres and workers of the smelter, prompting the cadres and workers to work hard to change their ideological understanding and concepts. Every week, the smelter organizes middle-level managers and cadres and workers to carry out special studies through different forms, in-depth study of Xi Jinping's Thought on Ecological Civilization and the spirit of General Secretary Xi Jinping's three important instructions and instructions to China Nonferrous Metals Group, and carefully study the "Yangtze River Protection Law of the People's Republic of China", etc., further strengthen the study of new development concepts, Yangtze River Protection Law, and Yangtze River Economic Belt ecological and environmental protection plans, and fight the battle to defend blue sky, clear water, and pure land with higher standards. At the same time, we carried out system revision and publicity. Through review of problems, we checked for the lack of the system. We analyzed the weak points and ambiguities of the system in real cases, conducted in-depth discussions, checked and clarified more than 80 problems, and revised 35 systems. Expert teachers were invited to give lectures. In accordance with the principle of professional matching, some middle-level managers gave lectures before taking the stage, organized team staff to learn the system, job operation procedures, homework instructions, etc. at the workshop level. The whole factory organized a total of more than 240 special studies (times). Through in-depth and systematic study, all trainees continuously strengthen their ideological and cognitive levels, improve their political stance, and improve their management capabilities.
With the normalization of learning, keywords such as lucid waters and green mountains, garden-style factories, intelligent production, standardized operations, and profit improvement have caused fierce collisions in the minds of cadres and workers. Employees have also changed from passive "requiring learning" to "Active learning", the change in the ideological understanding of all employees, making the path of rebirth of environmental protection upgrades and transformation a conscious action of all employees.
Green rebirth: The gorgeous turn of the old factory area
The central ecological and environmental protection inspector has revitalized the old factory area. After the technology upgrade, environmental pollution has been reduced, the factory environment has become cleaner, and the happiness of employees has been significantly improved. Job seekers came here during the recruitment season. People saw the rebirth and future of a modern factory and the responsibilities and responsibilities of central enterprises in green development.
Cheng Yakun, a stove worker who has worked hard in the smelter for nearly 30 years, shared the changes in his working environment with joy. "I never thought that this smelter, once intertwined with gray fire and choking smell, would one day transform into a tree-lined garden factory."
Once upon a time, Cheng Yakun faced the heat and smoke in front of the stove every day. With the upgrading of environmental protection and the deepening of environmental protection concepts, the smelter has undergone earth-shaking changes. Nowadays, Cheng Yakun rarely needs to go to the site personally to operate. He sits in front of the computer in the smart operation center and can easily monitor and control the entire production process through the screen. More than 30 key positions in the plant have achieved centralized monitoring, intelligent calculation and automatic control, and some difficult positions such as converters have even achieved unmanned operation. This change not only makes the working environment more comfortable, but also greatly improves the stability of process and production control.
It is worth mentioning that the smelter has made significant breakthroughs in intelligent transformation. The converter adopts advanced technologies such as infrared temperature measurement and endpoint determination to realize remote one-button shaking operation. This is the first time in the field of copper smelting converters in the country. Through the DCS control system, the factory can achieve real-time control of the production process and achieve precise control in aspects such as safety and environmental protection, energy management, and cost control. This transformation from centralized control to centralized management has truly achieved the goal of smart operations.
With the commissioning of environmental protection upgrades and renovation projects, Cheng Yakun and his colleagues have strengthened their thinking of green development and gained a deeper understanding of Xi Jinping's thoughts on ecological civilization.
On November 15, 2023, the pilot production work of the smelter system transformation will be fully launched. After the transformation, the environmental quality of the smelter has reached the advanced level in the industry. In terms of water, rainwater is treated and reused in the early stages of the plant area. Sewage is discharged after being treated to reach Level A standards. After treatment, production wastewater is used to replenish water and slowly cool and wash slag, and is not discharged; in terms of gas, the dispersion of flue gas in the smelting plant area has been eradicated, and the content of discharged sulfur dioxide and particulate matter in the discharged tail gas is only half of the special emission limit, which is at the first-class level in the industry.
After the fourth sulfuric acid series was stopped and one converter was suspended, flue gas emissions dropped by 12.5%. The "zero emission" transformation of acidic wastewater was implemented. After advanced treatment and hardness reduction, all acidic wastewater was used to replenish water in the cooling system without being discharged. After the project was completed, the smelter's heavy metal emissions dropped by 13.7%.
It is estimated that in 2024, the smelter will achieve an annual output of nearly 500,000 tons of cathode copper, operating income of nearly 40 billion yuan, total profit of 370 million yuan, and contribute 100 million yuan in tax revenue. The plant will save 3200 tons of coal and 60 million kilowatt-hours of electricity annually, reducing carbon dioxide emissions by 13,000 tons, reducing annual costs and increasing efficiency by approximately 220 million yuan. A modern and intelligent green copper smelter will surely glow with unprecedented vitality and show the smelting style of the new era.
Looking forward to the future, Zhongse Daye Smelter will be guided by Xi Jinping Thought on Ecological Civilization and take the rectification of the central ecological and environmental protection inspector as an opportunity to take more solid steps in energy conservation, carbon reduction, and green development, and effectively fulfill the ecological civilization construction of central enterprises. Political responsibility for ecological and environmental protection, and unswervingly follow the path of green and high-quality development.
