Focus on refractory production
Refractory manufacturing companies must strive to create a green benchmark factory
Refractory materials are indispensable basic materials for the development of high-temperature industries such as steel, cement and glass. Since the reform and opening up, China's refractory industry has made great progress and has become the world's largest producer, consumer and exporter. As the production unit of the manufacturing industry, the factory is the main body of green manufacturing and the core supporting unit of the green manufacturing system.
In order to implement China's green manufacturing strategy and implement the green manufacturing standardization system, the Ministry of Industry and Information Technology issued the Notice on the Construction of a Green Manufacturing System. The notice clarifies the overall thinking, construction principles, construction goals and construction contents of the green manufacturing standard system. , program arrangements and safeguards. The green manufacturing system is divided into four systems: green factory, green product, green park and green supply chain. The green factory is a factory with four characteristics of land intensive, clean production, waste resource and low carbon.
The evaluation of the green factory helps to set the benchmark in the industry, guiding and standardizing the factory to implement green manufacturing. At the same time, under the principle of market-driven driving and supplemented by government guidance, it provides guarantee for the promotion of the visibility and influence of advanced demonstration green factories. The government financial reward system will also serve as one of the incentives to enable enterprises to obtain real benefits. Inspire the endogenous motivation of the company's green development. Up to now, Anhui Province and Henan Province have issued relevant funds to encourage green manufacturing system incentive policies to provide guarantees and incentives for the establishment of green manufacturing systems for local enterprises.
1 Green factory evaluation requirements
The green factory evaluation requirements include two parts: the general rules and the evaluation indicators. In general, the evaluation index framework, evaluation basis and evaluation method are introduced in detail. The evaluation indicators stipulate the evaluation points in the green factory evaluation process and the basic requirements and expected requirements that the enterprise needs to meet.
The green factory is the production unit of the manufacturing industry and the main body of green manufacturing. It mainly focuses on creating factories that are characterized by intensive land use, clean production, waste resources, and low-carbon energy. The plant is rebuilt by adopting relevant energy-saving technologies. Renewable energy applications, rational layout of the plant area and the adoption of clean production technologies to achieve green development of the plant. The green factory evaluation process is a comprehensive evaluation of the plant's energy and resource inputs, production processes, products, environmental emissions, and environmental performance under the conditions of establishing a management system and existing infrastructure.
2 evaluation indicators
The green factory evaluation indicators are divided into first-level indicators and second-level indicators. The first-level indicators include: general requirements, infrastructure, management systems, energy resources input, products, environmental emissions, and performance. The specific requirements include basic requirements and expectations. The third-party evaluation agencies are required to score the evaluation indicators by reviewing report documents, statistical reports, original records, on-site discussions, and field surveys. The enterprise must conduct green factory evaluation under the conditions that meet the basic requirements. The expectation requires each enterprise to report truthfully according to the actual situation. It is the characteristic item and additional item of the green factory declared by the enterprise, and it is the key to the success of the green factory. effect.
Analysis on Key Points of Green Factory Construction of Refractory Brick Production Enterprises
Refractory materials are indispensable basic materials for the development of high temperature industry. Since the reform and opening up, China's refractory industry has made great progress and has become the world's largest producer, consumer and exporter. According to incomplete statistics, there are about 2,000 enterprises above designated size in the national refractory industry, with an annual output value of 200 billion yuan. In 2016, the national refractory output was 2,391,240 tons, of which the output of dense shaped refractory products was 13.58 million tons, the thermal insulation refractory products were 467,200 tons, and the amorphous products were 9,859,900 tons.
From January to September of 2018, the national refractory output of the same caliber was 14.6895 million tons, an increase of 3.25%. Among them, densely shaped refractory products were 910.32 million tons, up 2.27% year-on-year; thermal insulation refractory products were 443,200 tons, up 21.74% year-on-year; unshaped refractory products were 5.395 million tons, up 3.64% year-on-year.
1 general requirements
The factory complies with the requirements of laws, regulations and policies during the construction process, and has no major safety, environmental protection and quality accidents in the past three years. For enterprises established less than three years ago, there is no relevant accident since the establishment of the factory. In the evaluation, the company's business license, environmental assessment approval and completion acceptance documents are used to determine whether the requirements are met. The enterprise also needs to make commitments to the stakeholders' environmental requirements and meet the requirements of the commitments. It can conduct self-evaluation or third-party evaluation through the pollutant detection report provided by the third-party testing organization, and make corresponding commitments. In addition, the top management of the company should assign the responsibility and authority related to the green factory, and set up a green factory management organization to set the annual target and implementation plan for the medium and long-term planning and quantification, as well as provide regular green plant related education and training to form The “Green Factory Management Manual” was issued and implemented, and the education and training records related to the green factory were retained.
The infrastructure indicators shall be standardized for the construction, lighting and equipment of the factory. The factory buildings shall comply with relevant laws and regulations, and the harmful substances such as aldehyde, benzene, ammonia and hydrazine in the interior decoration materials of the factory shall comply with relevant laws. As required by the standards, the factory has a special dangerous goods warehouse, toxic and hazardous operation rooms, and waste disposal rooms. The use of energy and resources enables classification and measurement. In addition, the green factory evaluation requirements focus on energy conservation and emission reduction, so in the production and workplace lighting density in line with the provisions of GB50034, encourage enterprises to use natural light lighting.
In the infrastructure indicators, refractory brick enterprises need to clarify the key points of the company's plant area, plant facilities, office areas, living area layout and plant environment. When constructing, rebuilding and expanding buildings in the factory, we will abide by the industrial policies and related requirements of the National “Fixed Assets Investment Assessment Project”, “Three Simultaneous Systems” and “Industrial Project Construction Land Control Indicators”. Whether the production and storage related workshops adopt steel structure and multi-storey construction methods, whether the raw materials in the plant construction process use low energy, high performance, high durability and local building materials, etc., and at the same time increase the greening rate of bare land in the production area, increase The proportion of outdoor permeable area in the total outdoor area. Hazardous waste generated by refractory brick production enterprises, such as waste mineral oil, should be set up in a special storage place and entrusted by a qualified third party to handle it regularly. The factory is equipped with measuring instruments and devices for power and water resources according to the requirements of GB17167 and GB24789. It is equipped with a classification and classification measuring system for lighting systems, energy-using equipment, indoor and outdoor water, and periodic implementation of energy-using units for energy-using units. External inspection. When the factory office area and factory building are constructed, natural light-transparent materials are considered to reduce energy consumption. Energy-saving measures can be adopted in the plant area through intelligent centralized control of regional and time modes, and configuration of lighting photosensitive control sensor switches, infrared presence switch sensors, and infrared ultrasonic motion sensors.
3 management system
At present, refractory production enterprises have generally established three systems of quality management system, environmental management system and occupational health and safety management system. The establishment of energy management system based on the requirements of GB/T23331-2012 energy management system is still not perfect, and energy management is An important management tool for implementing energy-saving work in the green factory creation work is recommended to be regulated by self-establishment or third-party certification.
The social responsibility of an enterprise can prove the requirement of meeting the expected indicators by issuing a publicly available social responsibility report every year. The organization of the factory or factory shall prepare a social responsibility report according to the requirements of GB/T36000-2015, ISO26000 or SA8000, indicating the performance. The situation of stakeholder responsibility, especially the implementation of environmental social responsibility. The social responsibility report can be compiled from the perspectives of corporate culture and corporate responsibility for employees, consumers, the environment, society and other stakeholders. By publishing social responsibility reports, enterprises can achieve the role of enhancing corporate social image, strengthening communication between enterprises and external parties, and stimulating enterprises to fulfill their social responsibilities.
4 energy resources investment
The main energy-consuming links in the production process of shaped refractory bricks are mainly processes such as crushing, forming, drying and firing. Among them, crushers, presses, etc. mainly consume electricity, and kiln equipment such as drying kiln and tunnel kiln mainly use heavy oil or natural gas. Therefore, in terms of energy conservation, enterprises should mainly consider measures such as improving crushing efficiency and electric press reform to achieve power saving purposes; in addition, kiln that uses heavy oil as fuel input should also include natural gas and electric kiln reform in the next step. Clean energy transformation plan.
The main raw materials used in the refractory production process include natural mineral raw materials such as magnesite, kaolin and mullite. At present, some factories have recycled the refractory materials such as downstream steel metallurgy and cement rotary kiln, and reused them to the production of new bricks. This has reduced the use of raw materials to a certain extent, and at the same time eliminated the supply chain. Solid waste, which has positive significance for the future refractory industry and upstream and downstream industries to jointly create a green supply chain.
Chromium-free refractories as the mainstream of the development of refractory industry, enterprises that are still producing refractory bricks such as magnesia chrome bricks should actively consider transformation, and resolutely eliminate the production of chrome-containing bricks by improving product formula and considering alternative raw materials. Downstream refractory bricks use enterprises to eliminate the input of harmful substances such as hexavalent chromium from the source.
In the product indicators, the ecological design of the product, the restricted use of hazardous substances, energy conservation, carbon footprint and recyclability will be taken into account, and environmental factors will be incorporated into the design and production of the product without affecting the performance and safety of the product. Reduce the use of consumables and hazardous materials and increase the utilization rate of renewable materials. Integrate the concept of greenhouse gas reduction into the factory, and reduce greenhouse gas emissions during the product life cycle by conducting product carbon footprint quantification and verification. In addition, the product's carbon footprint can be identified in the product packaging or in the instructions to convey the carbon properties of the product to consumers and society.
6 environmental emissions
Refractory bricks, especially refractory materials, which are mainly non-fired bricks such as magnesia carbon bricks, are the main factors that need to be concerned with environmental emissions, such as dust and noise, and high alumina bricks with high-temperature firing technology. It is also necessary to pay attention to the emission of atmospheric pollutants such as sulfur dioxide and nitrogen oxides generated during the firing process.
In addition, since the water supply link in the past is not the focus of the factory, many companies have not done enough to recycle and recycle the living and production wastewater.
In the production process of refractory materials, greenhouse gas emissions are mainly indirect emissions such as electricity consumption. At present, some provinces have required the refractory production enterprises in the province to verify the greenhouse gas emissions of enterprises as required and declare them, but most enterprises have not yet established a complete system plan for greenhouse gas inventory, management, and emission reduction.
The Green Plant Evaluation Requirements gives detailed performance calculation methods, which give specific requirements for plant intensification, material harmlessness, production cleanliness, waste recycling, and energy low carbonization. Under the premise of meeting the basic requirements, environmental performance is the main aspect of green factory evaluation, which is mainly composed of ten main indicators. Environmental performance indicators are compared around the same industry. It is necessary to fully consider the characteristics of the industry and grasp the evaluation scale based on industry-related data.
conclusion and suggestion
The creation of a green factory breaks the principle of the creation of factories in the past, focusing on the creation of factories that are characterized by land intensification, production cleanliness, waste recycling, and low-carbon energy, taking into account the establishment of management systems and existing infrastructure conditions. Comprehensive requirements for energy and resource inputs, production processes, products, environmental emissions, and environmental performance. For refractory manufacturers, the focus of the green plant needs to be based on the optimal management and layout of infrastructure in the plant area, the development of new environmentally friendly products, the use of energy cascades, the improvement of energy efficiency, energy conservation and consumption reduction, and comprehensive emission reduction. Expanding, achieving efficient recycling of resources, reducing energy consumption, material consumption and water consumption levels, continuously improving the utilization rate of green and low-carbon energy, carrying out green and low-carbon transformation, and taking the road of sustainable development, can become the benchmark for leading the development of refractory industry.