Efficiency and Cost Reduction in the Second Quarter at Zhongnan Steel's Smelting Plant
Jul 03, 2024
The second quarter has seen stable and efficient production at Zhongnan Steel's smelting plant. Through meticulous energy conservation and consumption reduction, extreme energy efficiency, and the repair and reuse of old equipment, the plant achieved cost savings of over 55.41 million yuan in April and May, with a cost reduction of more than 42 yuan per ton of steel. This has led to the plant exceeding its monthly target for two consecutive months. In the first 20 days of June, the cost savings amounted to 12.46 million yuan, with a total cost reduction of over 67 million yuan for the second quarter, surpassing the quarterly target and making a positive contribution to overcoming the steel industry's winter.
Starting from the source, the smelting plant has actively enhanced management efficiency in its cost reduction and efficiency improvement efforts. With key performance indicator competitions as the focus, the plant has solidly advanced the effective implementation of cost reduction and efficiency improvement. By benchmarking against industry leaders and changing mindsets, the plant has introduced a series of measures to reduce costs and increase benefits. The special steel sector has achieved a historic breakthrough in several cost reduction indicators such as shortening refining time and reducing refining electricity consumption. Through control of consumption reduction and structural adjustment, the plant has achieved a cost reduction of 14.13 million yuan in steel materials within two months. Additionally, through alloy substitution, scrap ingot recovery, narrow band control, and composition adjustment, the plant has realized an alloy cost reduction of 10.54 million yuan.
The second steelmaking workshop area has innovated in management from the careful preparation of pig iron raw materials to shortening the smelting cycle and refining time in the converter, and the integrated connection between processes. While continuously strengthening management and optimizing production, the plant has focused on energy conservation and consumption reduction. The use of class 06 scrap steel for recycling and the addition of scrap ingots containing precious alloys in refining have continuously expanded the breadth and depth of cost reduction and efficiency improvement, achieving a monthly cost reduction of 41.4 yuan per ton and a total cost reduction of 13.95 million yuan.
The second continuous casting workshop area has cast a wide net, starting from various production links to deeply explore cost space and eliminate all waste phenomena. Adhering to the principle of "repair if possible, and transform if possible," the workshop area has actively sought methods to reduce loss with the goal of repeated use. For the wear and tear issues of consumables such as stop cones, nozzle mops, and crystallizer covers, the workshop area has adopted the principle of repairing or transforming whenever possible, greatly reducing the cost of loss through repair and reuse. At the same time, the workshop area has actively promoted the concept of waste utilization and recycling, using waste materials for secondary use, further reducing production costs. In the operation, crystallizer covers are prone to sticking to molten steel and were usually scrapped, but now they are cleaned and repaired. After repair, the performance and quality of the covers meet the standards and can be put back into production. Since the second quarter, the loss of covers has been reduced to zero, reducing costs and improving resource utilization.
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