The design and construction concept is “great for the ocean”; the equipment is running “big horse cart”; a large number of equipment “work with disease”... These are some “common problems” during the service of metallurgical equipment in China. In the context of the meager profit operation of the whole industry, the intelligentization of metallurgical equipment and in-service remanufacturing has risen to a strategic height, and the era of large-scale production, that is, user-oriented scale customization is approaching.
At the 2014 Steel Industry Technology Innovation Conference held recently, Li Chongjian, chief engineer of the Metallurgical Automation Research Institute, said that in the future, the intelligentization of metallurgical equipment and in-service remanufacturing should focus on the development of intelligent monitoring, matching equipment and processes, and improving overall system energy efficiency. . To this end, the design level should proceed from the system process energy efficiency, modify the equipment design specifications and standards; the demonstration project needs to arrange technical model demonstration, application engineering demonstration, factory demonstration, and establish equipment remote monitoring and energy efficiency monitoring platform.
Zhou Ji, dean of the Chinese Academy of Engineering, said that the intelligentization of metallurgical equipment and in-service remanufacturing is an important part of the strategy of “manufacturing a strong country”. It closely matches the core technologies of a new round of scientific and technological revolution and industrial transformation, such as digitalization, intelligence and networking. Integrate information technology and manufacturing technology to develop the concept of “Industrial Internet”.
Equipment level is advanced
In order to explore the development strategy and specific path of metallurgical equipment intelligence and in-service remanufacturing, China Iron and Steel Association, steel enterprises, universities and research institutes set up high-end energy power machinery health and energy efficiency monitoring intelligentization on December 27, 2003. Development Strategy Research and Process Industrial Machinery Equipment In-service Remanufacturing Engineering Strategic Research Metallurgical Project Team. At present, the project team has formed a preliminary draft of the research report.
According to the research report, in coking production, there are currently more than 2,200 coke ovens in China and 55 coke ovens with more than 65 holes. In the iron production, there are more than 1,480 blast furnaces in the country and more than 480 large blast furnaces above 1000m3. The blast furnace ironmaking equipment mainly includes blast furnace blowers, blast furnace dust fans and cooling water pumps. In steel production, China's steel enterprises have about 810 converters, nearly 360 circuits; steel production and electricity accounts for 25% of metallurgical production. In addition, in the steel rolling production, China has a total of 81 sets of hot strip mills with a capacity of about 232 million tons; 76 sets of plate mills with a capacity of about 92 million tons; the rolling mill production line put into operation this year integrates the most advanced rolling technology of the contemporary, using distribution The computer system performs transmission control and basic automation control, which lays a foundation for the production of high quality steel materials.
However, at present, the sustainable development of China's metallurgical industry still faces many problems. On the one hand, there is a serious overcapacity, and the capacity utilization rate is less than 70%. On the other hand, the task of energy conservation and emission reduction is very arduous. In some areas, steel pollution emissions have exceeded environmental carrying capacity. Most steel companies have not achieved pollutant discharge standards, and there is a huge gap between the national energy conservation and environmental protection requirements.
In this context, the intelligentization of metallurgical equipment and in-service remanufacturing are particularly important. According to the definition, equipment in-service remanufacturing refers to the use of information technology and intelligent technology to technically transform the equipment that runs online. It aims to achieve the safe and healthy operation of metallurgical machinery and equipment, the matching of equipment and production process, and promote the efficient operation of the system. Energy-saving emission reduction of metallurgical production; at the same time, adapt to the needs of the steel industry to transform to scale customization.
Intelligent level needs to be improved
The research report believes that the current state of service of China's metallurgical equipment mainly presents the following three characteristics: First, after more than 30 years of rapid development of “big steelmaking”, China's metallurgical equipment level has increased significantly, but equipment is generally greedy and seeks foreign design. And the construction concept is not scientific, the equipment runs “big horse trolley”; second, the domestic metallurgical equipment and production technology are not enough. The advanced metallurgical equipment lacks the mining and utilization of production data, the equipment operation and production process, the product quality is not suitable, and the design and actual operation of the “big horse trolley” phenomenon is serious. Third, in the context of current overcapacity, the profits of steel companies have declined, equipment maintenance and spare parts renewal have faced difficulties, and a large number of metallurgical machinery and equipment have “worked with disease”.